WAR DEPARTMENT
TECHNICAL MANUAL
MAINTENANCE
AND CARE OF
HAND TOOLS
WAR DEPRTMEIENT
.
APRIL 1945
WAR DEPARTMENT TECHNICAL MANUAL
TM 9-867
MAINTENANCE
AND CARE OF
HAND TOOLS
WIAR DEPAR TMENT
APRIL 1945
WAR DEPARTMENT
Washington 25, D. C., 19 April 1945
TM 9-867, Maintenance and Care of Hand Tools, is published for
the information and guidance of all concerned.
A.G. 300.7 (20 Nov43)
0.0. 461/60440 Raritan
BY ORDER OF THE SECRETARY OF WAR:
G. C. MARSHALL,
Chief of Stafi.
OFFICIAL:
J. A. ULIO,
Major General,
The Adjutant General.
DISTRIBUTION: AAF (10); AGF (5); ASF (2); Dept (10); AAF
Comd (2); Arm & Sv Bd (1); S Div ASF (1);
Tech Sv (2); SvC (10); PC&S (1); PE (Ord O)
(5); Dist O 9 (5); Dist Br O 9 (3); Reg O 9
(3); Establishments 9 (5); Decentralized Sub
O 9 (3); Gen & Sp Sv Sch (10); USMA (20);
A (10); CHQ (10); D (2); B 2, 4-8, 18, 44 (1);
R 2, 4-11, 17-19, 44, 55 (1); Bn 2-11, 17-19, 44,
55 (1); C 2-11, 17-19, 44, 55 (1); AF (2);
W (1); G (1); S (1); F (1).
Refer to FM 21-6 for explanation of distribution formula.
TM 9-867
CONTENTS
Section
I
II
Page
Introduction
...................................
Abrasive Wheels and Oilstones ...................
5
III
Awls
IV
Bits and Boring Tools ...........................
14
V
Braces and Hand Drills ..........................
24
Brushes ........................................
26
VII
Calipers
.......................................
29
VIII
Chisels
........................................
33
Clamps ........................................
39
Dividers
42
VI
IX
X
XI
..........................................
2
.......................................
11
Files and Rasps ................................
44
Hammers, Mallets, Mauls, and Sledges............
47
XIII
Hand Grinders .................................
51
XIV
Hatchets, Axes, Mattocks, Adzes, and Shovels......
53
Hydrometers
58
XII
XV
...................................
XVI
Knives
.......................................
59
XVII
Levels
........................................
62
XVIII
XIX
XX
XXI
XXII
Nippers and Pliers ..............................
64
Planes
67
........................................
Punches
.......................................
74
Reamers .......................................
77
Saws
79
..........................................
XXIII
Scrapers
XXIV
Screwdrivers
XXV
XXVI
XXVII
XXVIII
XXIX
XXX
.......................................
...................................
Shears ........................................
89
92
96
Soldering Irons ................................
100
Taps and Dies ...............................
Vises ..........................................
Wrenches .....................................
References .....................................
103
107
109
112
1
TM 9-867
Section I
INTRODUCTION
PURPOSE AND SCOPE
This manual is published for the information of arms and services
charged with care of hand tools. It is intended to serve as a guide
and ready source of definite information for personnel having some
previous knowledge in the operations covered. Insofar as practicable, descriptive and use-of-tools information is omitted in order
to devote more space to care of tools. The efficiency of a mechanic
and the tools he uses are determined to a great extent by the condition in which that mechanic keeps the tools. Likewise a mechanic
can be judged by the manner in which he handles and cares for
tools. Micrometers, or any other precision tool, must be handled
with a careful, delicate touch and precision, commensurate with the
extreme accuracy with which these tools are capable of measuring.
It is with joy and great interest that everyone watches a skilled
mechanic at his work, and this is largely due to the care and precision with which he uses the tools of his trade. There is a place for
every tool and he keeps each tool in its place. He carefully wipes
his tools clean and dry before he places them in the tool box. If he
does not expect to use a tool again for some time he lubricates it to
prevent rusting.
NOTE: When storing tools under conditions of extreme humidity,
moisture or salt air, it may be desirable to use preservative lubricating oil (medium) instead of the preservative lubricating oil
(special) or engine oil (SAE 10) prescribed in this manual for
normal conditions.
LIST OF TOOLS
Abrasive Wheels and Oilstones
Abrasive wheels
Oilstones
Braces and Hand Drills
Braces
Breast drills
Hand drills
Awls
Handled seat awl
Brad awl
Saddler's sewing awl
Brushes
Bits and Boring Tools
Auger bits
Countersink bits
Expansive bits
Screwdriver bits
Twist drills -
Painter's dust
Sash tool
Steel wire
Stencil
Varnish
2
TM 9-867
Calipers
Hand Grinders
Firm joint
Inside and outside micrometers
Inside and outside spring
Hatchets, Axes, Mattocks,
Adzes, and Shovels
Hydrometers
Chisels
Blacksmith's
Machinist's
Woodworker's
Knives
Draw
Pocket
Putty
Clamps
C-type
Hand screw
Hydraulic brake cylinder
Toolmaker's
Levels
Nippers and Pliers
Nippers
Diagonal side cutting
Heavy type
Light type
Dividers
Spring
Wing
Files and Rasps
Round
Half round rasp
Flat
Taper
Pliers
Adjustable combination
Brake spring
Flat-nosed
Half round-nosed
Round-nosed
Side cutting
Tire chain repair
Hammers, Mallets, Mauls,
and Sledges
Hammers
Bell faced claw
Blacksmith's cross peen
Blacksmith's straight peen
Ding weight
Machinist's ball peen
Plain faced claw
Riveting
Soft face (copper, lead,
leather, plastic, rawhide,
rubber)
Trimmer's
Mallets
Mauls
Sledges
Blacksmith's cross peen
Blacksmith's straight peen
Planes
Bench
Fore
Jack
Smooth
Block
Punches
Hollow
Solid
Center
Pin
Prick
Taper
3
TM 9-867
Reamers
Hand reamers
Straight
Taper
Expansion
Adjustable
Power reamers
Straight
Taper
Shears
Bench
Bolt cutters
Curved blade tinner's
Scroll pivoter snips
Straight blade tinner's
Soldering Irons
Electric
Nonelectric
Saws
Back
Bead
Compass
Coping
Crosscut
Dovetail
Hack
Keyhole
Miter box
Nested
Patternmaker's
Rip
Stairbuilder's
Veneer
Taps and Dies
Taps
National series hand taps
Pipe
Dies
National series round dies
Pipe dies
Square
Four piece
Vises
Blacksmith's
Machinist's
Pipe
Utility bench
Scrapers
Bearing
Carbon
Flat
Three-cornered
Wrenches
Screwdrivers
Clutch-head
Offset
Phillips type
Spiral ratchet
Standard
Adjustable
Box
Open end
Pipe
Socket
Socket head set screw
4
TM 9-867
Section II
ABRASIVE WHEELS AND OILSTONES
FLARING
CUP
STRAIGHT
BEVELED
RA PD
87173
ANGLE FACE RECESSED ONE SIDE OFFSET AND RECESSED
ABRASIVE WHEELS
Maintenance
* Handle wheels with care at all times; they break easily.
* Do not grind on sides or corners of wheel, unless it is impossible
to grind the job at hand on the face of the wheel. This rule
should be observed, due to the difficulty of dressing the sides
of the wheel.
* When mounting wheel on spindle observe the following precautions:
RA PD 87174
Test wheel by tapping with a cellulose face or rubber face hammer
or mallet. A ringing sound indicates a satisfactory wheel. A dull
thudding sound indicates a cracked wheel. Do NOT use a cracked
wheel.
GASKET
RA PD 87175
Be sure wheel is equipped with blotter paper gaskets or safety
washers on each side. If safety washers are used, remove paper from
wheel and fit rubber sides next to wheel.
5
TM 9-867
Do not force wheel onto spindle. It must slide on easily with 0.003to 0.005-inch clearance.
RA PD 87177
Tighten spindle nut just tight enough so flanges hold wheel firmly.
Overtightening may crack wheel.
After installing, test wheel for breakage by starting. CAUTION:
Stand clear!
* If wheel glazes easily (cutting particles become dull), decrease
its speed or use softer wheel.
* If wheel loads easily (pores or spaces between cutting particles
clog with material being ground), increase its speed or use
softer wheel.
Truing
Removal of material from cutting face of a wheel so surface
runs true.
Dressing
Restoring sharpness of a wheel
face which is "loaded" or dulled.
aS
*
On grinding machines, these operations are best done with a
diamond dressing tool rigidly supported in a fixed tool post. Abrasive wheel dressers and abrasive type dressers are used on bench
or pedestal grinders.
4-CUTTER TYPE DRE
TUBE TYPE DRESSER
RA PD 87178
6
TM 9-867
1. Set tool as shown, almost
in contact with high point of
wheel.
2. Start wheel rotating. Start
10 TO 15
tool traversing and feed into
wheel 0.001 to 0.002 inch at
end of each pass until contact is made.
TvDIAMOND
{
3. Traverse cutter back and
+
forth across wheel face, using
TOOL HOLDER-
0.001-inch feed until sound
RA PD 87179
indicates dresser is cutting
all around the wheel.
NOTE: For wet grinding, dress wet. For dry grinding, dress dry.
WHEEL DRESSER
GRINDER REST
\k
J o~
~_
',~'~J
V
D J US T
~~~A'-"'J
"
REST AWAY FROM
'WHEEL
TO PERMIT LEG OF
*~a/~
WHEEL DRESSER TO GUIDE
ON FRONT EDGE OF REST
RA PD 87180
rs
1. Adjust tool rest to permit wheel dresser to contact abrasive wheel
on centerline of wheel as illustrated.
2. Start wheel revolving, then support the dresser on tool rest with
handle tilted upward at angle shown in illustration.
3. Slowly press the wheel dresser against face of revolving wheel
until it "bites," then move dresser from side to side across wheel
to obtain a straight surface on the wheel. CAUTION: Hold the
dresser rigidly enough on tool rest to prevent vibration.
4. Smooth wheel by passing an abrasive type dresser back and
forth over the face of the wheel as shown below, smoothing with a
very light pressure.
ABRASIVE WHEEL DRESSER
RA PD 87181
7
TM 9-867
Common Misuses and Abuses
Do not operate wheel which has worn to a small diameter at same
revolutions per minute as when new. This causes wheel to act
excessively soft and wear fast because of the much reduced speed
of grinding surface. Increase revolutions per minute to make up for
smaller size.
Wheels not in use must be stowed
in racks. If left on the floor they are
apt to get broken.
Storage
Suspend wheels through their spindle
holes in racks in a dry place, or store
them in individual boxes.
RA PD 87182
OILSTONES
SQUARE
TIANGULAR
TRIANGULAR
C4ROLIND
ROUND EDGE SLIP
RA PD *7183
Maintenance
* Soak new oilstone in engine oil (SAE 10) before using.
* Prevent glazing by application of engine oil (SAE 10) during
use of stone.
* Wipe stone clean with wiping cloth or cotton waste after each
use.
* SOAK IN OIL
0 USE LUBRICANT
8
0 WIPE AFTER USE
RA PD 87184
TM 9-867
Cleaning
Wash glazed or "gummed up" stone with dry-cleaning solvent or
aqua ammonia. If this treatment fails to completely clean stone,
scour it with aluminum oxide abrasive cloth or flint paper attached
to a flat block.
Dressing
True uneven surfaces on coarse, medium, or fine oilstones on side of
an old grinding wheel, a grindstone, or as follows: Cover a smooth
cast-iron block with waterproof artificial abrasive paper. Place stone
on surface and lap in with water until true.
NOTE: Special shape stones can
be formed by making a groove of
mating shape in a cast-iron block.
Use waterproof artificial abrasive
paper and water and draw stone
through groove.
DRESSING OILSTC)
Repairing Broken Oilstone
or
0L~'^
-RR^A
RA PD 87187
PDO87186
Scrub pieces with dry-cleaning
solvent or aqua ammonia to
remove gum and dirt.
Heat pieces on a hot plate to
drive all oil from inside stone.
PD 87188
Dust broken edges thickly with
flake or ground orange shellac.
Carefully work shellac into all
cracks and openings.
;5
RA PD 87189
Reheat pieces to melt shellac,
and clamp together until cooled.
Dress stone if joints are uneven.
9
TM 9-867
If shellac is not available, mount broken pieces in wooden block.
Cut recess in block, exact size of stone, depth about one-half the
thickness of stone. Assemble pieces of stone and force into recess
in block.
Common Misuses and Abuses
Do not use stone dry. This causes glazing and clogging of stone.
Apply engine oil (SAE 10) (or water in an emergency) before using
stone.
WRONG
RA V
87190
RA PD
87191
RIGHT
Do not store stone in a hot place. Heat will cause oil to form a
gummy residue on stone. Store in a cool, moist place.
1I
I] -
i'
RIGHT
RA PD 87193
WRONG
RA PD 87192
Do not attempt to do a honing job with the wrong stone. Such procedure wastes time and energy and causes unnecessary stone wear.
Use stones as follows:
STONE
Coarse
USE
To sharpen large and very dull or nicked tools.
Medium
To sharpen ordinary mechanics' tools not requiring finished edge such as tools for working soft wood, cloth,
leather, and rubber.
Fine
To sharpen tools requiring a very fine edge such as
machinists', engravers', instrument workers', and cabinet
makers' tools.
Storage
Keep stone clean and moistened with engine oil (SAE 10). If stored
in a dry place, keep stone enclosed in a covered box.
10
TM 9-867
Section III
AWLS
FERRULE
-.
HANDLE
BLADE
CONE
/BRAD
AWL
/
Q(OO
5 PIECE
SADDLER'S
SEWING AWL
RA PD 87194
GRINDING AND TEMPERING
General
Normal order for reconditioning an awl blade is to harden, grind,
and sharpen. Usually all three operations are not needed. Harden
and temper only if tempered part has been broken off, worn, or
ground away, or if tool has been overheated. Grind after hardening
and tempering, or if blade has lost its shape from repeated
sharpening.
Hardening and Tempering
Heat about one and one-half inches of tip of blade to cherry red.
Use a gasoline torch, gas furnace, or charcoal fire. Do not overheat.
Quench about 3/4 inch of heated tip in clean, cold water to harden.
HEAT
RA PD 87195
QUENCH
RA PD
87196
Quickly rub hardened end with aluminum oxide abrasive cloth or
oilstone to brighten it. Watch color return to tip from heated
portion of blade and quench when light straw color arrives at point.
Polish blade with aluminum oxide abrasive cloth and crocus cloth.
11
TM 9-867
Grinding
RA PD 87198
RA PD 87197
Grind blade of cone-pointed
awl to point. Rotate awl during grinding to keep point centered. Be careful that the revolving wheel does not catch
the point and cause damage.
Dip blade frequently in water
or wet grind it.
If grinding a flat-pointed or
special shaped awl blade, hold
blade against abrasive wheel in
positions to preserve or restore
original shape.
Sharpening
Keep point sharp by frequently
giving it a few strokes on an oilstone. Rotate cone-pointed awl
slightly before each stroke. Do
not use too much pressure on
the tool, to avoid ridge marks
on the surface of the stone.
RA PD 87199
Replacing Handles
Clamp blade in soft-jawed vise and pull or tap old handle from
shank of blade. Pry ferrule from handle.
* Tap ferrule onto new handle. Prick punch ferrule to handle.
* Tap handle onto shank of blade and remove blade from vise.
·
FERRULE WSTALLATION
12
TM 9-867
Common Misuses
* Do not use an awl with a loose handle.
This often results in injury to the user.
Make sure the handle is tight, thus preventing the tang from,
injuring the user's hand.
·
Do not use the awl with a prying or lever action.
This results in breakage.
Exert force toward the point or cutting edge.
Storage
Dip awl in rust preventive compound (thin film). To protect the
point of the awl, insert the point into a small cork, a small, short
twig from a tree, or a soft wood block. Store in a dry place. Protect
blade from contact with metals. Upon removal from storage, wash
metal parts with dry cleaning solvent to remove rust preventive
compound.
13
TM 9-867
Section IV
BITS AND BORING TOOLS
K BIT
RA PD 87201
·-~~~~~~~~~~~I
FLUTE
PARTS OF A TWIST DRILL
14
THE POINT
RA PD 87202
TM 9-867
GRINDING TWIST DRILLS
General
Twist drills may be ground in a drill holder fixture or free hand.
Use fixture if available. Both methods are given in the following
pages.
Grind drill lips or cutting edges at an
angle of 59 degrees, as illustrated below
(50 to 60 degrees for drilling brass or
bronze, 68 degrees for extremely hard
material). Both cutting edges must
make same angle with drill axis, and
both cutting edges must be of same
length.
0 0
590
590
I
RIGHT
12oTO 15°
'-7
RA PD87204
10~
150
RIGHT
Grind heel to an angle of 12 to 15 de-
grees (9 degrees for drilling extremely
hard material). Failure to provide suffiRIGHT
cient clearance is the principal cause
of drills splitting up the web.
RA PD 87203
95
RIGHT
LIP
ANGLE
RA PD 87205
.......
.J.o.
-__
u
-
_ ...
6
15
TM 9-867
Some Common Grinding Faults to
Guard Against:
FAULT
RESULT
Lip angle excessive.
Drill will not center
properly because
cone-shaped point is
too flat.
WRONG
Lip angle too small.
WRONG
Only one cutting edge
Point on center but
cutting edges ground
to different angles.
"A
AND
"B"
UNEQUAL
1B
A
WRONG
Cutting edge angles
are equal but lips are
of different lengths.
DISTANCES
"A" AND "B'
/UNEQUAL
Insufficient heel angle
or clearance.
ANGLE
UNDER 120
WRON4G
Excessive heel angle
or clearance.
Drills slower and requires more power
because of longer
length of cutting
edges, and requires
frequent sharpening.
..-c.. l=WRONG
RA PD 87206
16
will do work. This results in rapid drill
wear and causes hole
to be larger than drill.
This throws point and
lip off center, causing
strain on drill, machine, and work, and
causing hole to
be
much larger than
drill.
Cutting edges lose
effectiveness. Drill
won't drill and may
split up center when
pressure is applied.
Cutting edges likely
to break down due to
excessive bite with in-
sufficient support.
TM 9-867
Using Drill Holder Fixture
*Exact procedure for grinding will vary with make of drill grinding
machine used. General procedure, which applies to conventional
type machines, is given in the following steps:
Adjust machine to desired cutting edge and heel angles. Refer
to illustrations of lip angle and heel angle (page 15).
Place drill in V-blocks of holder. Turn so cutting edge will contact abrasive wheel as drill is fed into wheel.
Start motor and advance tailstock until drill makes contact with
wheel.
Hold drill in place in V-blocks and swing holder spindle slowly
through its arc. Without changing tailstock adjustment, revolve
drill one-half turn in V-blocks and sharpen other lip of drill in
same manner.
_
u-
ABRASIVE WHEEL
V-BLOCK
DRILL
:.
I
I-
Inspect drill point to see if it has been ground back far enough to
eliminate all nicks. Repeat grinding and inspection operations until
perfect appearing points are obtained.
Free Hand Grinding
1. Adjust tool rest to a convenient
~'- 6-Ž'V--
height for resting back of forehand
on it while grinding.
RA Po 87208
17
TM 9-867
2. Hold drill between thumb and index finger of right or left
hand. Grasp body of drill near shank with other hand.
3. Place forehand on drill rest with centerline of drill making
desired angle with cutting face of wheel and slightly lower shank
end of drill as illustrated.
/
RESTn
RA PD 87210
RA PD 87209
4. Slowly place heel of drill
against grinding wheel. Then
gradually raise shank end of
drill and twist drill in fingers
in a counterclockwise direction
while grinding wheel approaches
the -utting edge. Exert only
enough pressure to grind the
drill without overheating. Frequently cool drill in water while
grinding.
5. Check results of grinding
with a gage to determine if cutting edges are same length and
at desired angle and if heel is
ground to angle of 12 to 15
degrees.
(
RA PD 87211
18
TM 9-867
Thinning Web
To strengthen a drill, the thickness
of web is increased as flute approaches shank. As point is ground
back, the web becomes thicker.
Ordinarily a web at the point of
greater than 1/32 to 1/16 of an inch
is objectionable. Grind down web
on a thin round or bevel edge
wheel to obtain web thickness of a
new drill of same size. Use care to
remove the same amount of metal
from each flute. A coarse handstone
may be used to obtain the dimension when a grinding wheel of the
proper width is not available. Hold
drill flat on bench and stroke flute
away from point. Use care to keep
from stoning away drill land.
,
/
RA PD 87214
Sharpening Expansive Bits
Sharpen spurs and cutters on expansive bit per instructions given
for auger bit, below.
Grinding Screwdriver Bits
For method of grinding screwdriver bits, see section 24, "Screwdrivers."
Sharpening Countersink Bits
Use a taper file to sharpen cutting edges of rose countersink bits
as illustrated. Use extreme care to retain original shape of cutters.
RA PD 87215
19
TM 9-867
SHARPENING AUGER BITS
SHANK
AUGER BIT
SCREW
SPUR
TWIST
RA PD 87216
Sharpening Spurs
AUGER
:
Select an auger bit file or a
small mill file.
RA PD 872'17as
Hold auger bit against a solid surface with shank down as
illustrated.
spurs, using care to retain
original shape of spur. Stop filing when a fine bur appears on
cutting edge of spur. Check to
determine if spurs are equal in
RA PD 87219
length.
Remove bur from spurs with a light touch of file.
20
RA PD 872220
TM 9-867
Sharpening Cutters
Hold auger bit against a solid
surface with screw of auger bit
pointing down.
Lightly file each cutter on
top side. Use care to maintain
original chisel-like shape of cutting edge.
RA PD 87221
CUTTING
EDGE
RA PD 87222
viT•
Stop filing when a fine bur
appears on cutting edge.
Check to determine if cutting
edges contact surface of a board
at same level.
CUTTING EDGES
RA PD 87223
Common Misuses to Avoid
Never attempt to enlarge a hole by tipping drill sidewise. You are
likely to break or bend the drill or hurt yourself. Use a larger drill
or reamer to enlarge hole.
WRONG
RA PD
87224
RIGHT
21
RA PD
87224A
TM 9-867
Do not allow drills to overheat while in use or being sharpened.
Heating destroys temper and makes tool worthless. Use proper
cutting oil or compound when drilling metal other than cast iron.
Wet grind drills when sharpening.
WRONG
RIGHT
RA PD
R7775
To drive a drill into a socket or
sleeve, do not use a steel hammer
or other hard object. This would
damage cutting edges. First make
certain socket or sleeve and drill
shank are clean, then tap drill to
seat with a lead or brass mallet.
WRONG
RIGHT
RA PD 87225A
Do not place work-supporting blocks far from drill. "Springiness"
of work will snap off drill. Support work near drill and clamp
securely to prevent turning.
WRONG
RIGHT
22
RA PD 87226
TM 9-867
Do not allow drill to work
loose in chuck. This will
cause "chucking" and will
bur or break drill. Keep drill
tight in chuck.
RIGHT
RA PD 87228
WRONG
RA PD 87227
Never keep drills loose in tool boxes. This practice causes unnecessary dulling of cutting edges. Keep in a rack or divided box when
not in use.
WRONG
RIGHT
RA PD
87229
Storage
Coat bits and drills with rust preventive compound (thin film)
and store in a dry place. Use racks or divided boxes to protect
cutting edges from contact with metal. Upon removal from storage,
wash with dry cleaning solvent to remove rust preventive compound.
23
TM 9-867
Section V
BRACES AND HAND DRILLS
TYPICAL
BREAST DRILL
TYPICAL
HAND DRILL
4
JAWS
t
RATCHET
TYPICAL HAND BRACE
TYPICAL SPIRAL HAND DRILL
RA PD 87230
CARE
Keep holding screws tight at all times. Loose screws may permit
loose meshing of gears. This causes teeth to break.
Do not disassemble chuck except when necessary to make repairs,
because of danger of losing springs.
Do not let tool rust. Scour off rust with crocus cloth or fine
aluminum oxide abrasive cloth. Apply lubricating preservative oil
(special) or engine oil (SAE 10) lightly to surfaces which tend to
rust.
Keep tool lubricated at all times, in accordance with following
instructions:
24
TM 9-867
LUBRICATION DATA
TOOL
PART
LUBRICANT
Cap bearings
GREASE, general purpose, No. 0,
or GREASE, O.D., No. 0
Handle bearings
Ring and ratchet
mechanism
Brace
Ring and ratchet
Breast and
Sleeve and jaw
mechanism
Gear teeth
Handle bearings
Drill chuck
hand drills
mechanism
Spirals (push
type hand drills)
OIL, engine, SAE 10, or OIL,
lubricating, preservative, special
OIL, engine, SAE 10, or OIL,
lubricating, preservative, special
GREASE, general purpose, No. 0,
or GREASE, O.D., No. 0
Common Misuses and Abuses
WRONG
RA D 87231
Do not use tool with bit not
fully inserted into chuck.
This places a strain on jaws
of chuck and may break
drill. Insert bit fully into
chuck.
RIGHT
RA PD 87232
Do not use a "squeaking" brace or hand drill. A squeak means tool
is wearing. Lubricate before using.
SQUEAK
WRONG
RIGHT
RA PD 87233
Storage
For permanent storage, wash tool in dry cleaning solvent to remove
lubricants. Coat all metal parts of tools with rust preventive compound (thin film) and store in a dry place where tool will be safe
from accident.
Upon removal from storage, remove rust preventive compound
from metal parts by washing with dry cleaning solvent.
25
TM 9-867
Section VI
BRUSHES
PAINT AND VARNISH BRUSHES
Cleaning Brush After Using
After using brush, squeeze paint or varnish from brush by pressing
brush against inside of container. Do not rub brush across edge of
can, as that wears and breaks bristles.
RA PD
87235
26
TM 9-867
Pour small quantity of thinner as prescribed for thinning the particular paint, enamel, varnish or shellac with which the brush has
been saturated, into a shallow, widemouthed container. Work thinner
thoroughly into brush, making certain the base of bristles or hair in
setting has been thoroughly immersed.
When brush appears clean, disf
card the thinner and refill container
with clean thinner. Work brush in
this until all traces of pigment dis 4i K
-
appear from brush and until bristles
are soft and pliable. Dry cleaning
solvent may be used in an emergency
in place of synthetic enamel or volatile mineral spirits paint thinner.
87236
Cleaning Hardened Paint from Brush
NOTE: Never allow paint to harden on brush. Cleaning is often
impossible and always shortens brush life.
1. Scrape paint from bristles with a putty knife.
2. Soak bristles several hours in linseed oil (clear lacquer thinner
for lacquer brushes, alcohol for shellac varnish brushes), and clean
as above.
Miscellaneous Notes on Brush Care
1. Before using a new brush, tap bristles across edge of a board.
Remove all loose bristles which will appear at end of brush.
2. Never stand brushes, wet or dry,
on their bristles; once its bristles
"set" in a curve a brush is ruined.
3. In charging a brush with paint,
do not rub bristles over edge of
container to remove excess paint.
Tap bristles lightly against inside
of container.
4. "Break in" new brushes on first
coats. This will increase their pliability and elasticity.
5. Always clean brushes after each
use.
6. Always store brushes properly.
27
RIGHT
WRONG
RA PD 87237
TM 9-867
Overnight Storage
1. Drill small hole in handle of
brush.
1/
_
2. Suspend paint and enamel
brushes in linseed oil "keeper"
so that bristles and setting are
completely submerged, but do
>*
not allow bristles to touch bot-
WRONG
2
i
t
tom of container.
3. Brushes used with shellac
varnish will be cleaned immediately after use, wrapped in
paper and. kept flat, pending
?
?5
I
I
A
further use.
P
RA PD 87238
Indefinite Storage
1. Clean brush thoroughly and immerse
in linseed oil. Press out most, but not
all, of linseed oil.
2. Wrap in oiled paper or brown wrapRA PD 87239
ping paper and store flat.
3. Once every six months,
unwrap
brush and treat with linseed oil.
NOTE: Brushes used with lacquer or shellac varnish can be
wrapped in paper and stored dry.
Care
DUST BRUSHES
Blow dust from brush with compressed air.
Clean soiled or stained brushes with dry cleaning solvent. Press
solvent from bristles and suspend brush by handle until dry.
Storage
Clean brush and wrap in paper. Store brush in flat position.
Care
WIRE BRUSHES
Clean brushes in dry cleaning solvent and blow dry with compressed air.
Storage
Apply rust preventive compound (light) to bristles. Wrap
greaseproof wrapping paper and store in a dry place.
in
Common Misuses and Abuses
Improper cleaning and improper storage are the most common
abuses of brushes. Clean and store brushes in accordance with
instructions above.
28
TM 9-867
Section VII
CALIPERS
FIRM JOINT CALIPER
(HERMAPHRODITES)
INSIDE MICROMETER
CALIPER
INSIDE
SPRING
CALIPER
OUTSIDE
MICROMETER
CALIPER
OUTSIDE SPRING
CALIPER
RA PD 87240
~,t
General
MAINTENANCE
Calipers are precision instruments and must be used and handled
with care at all times. Wipe perspiration and fingerprints from
them with a soft cloth; if neglected, this may cause rust. Do not
force threaded parts. Use touch measurement. Do not spring or
clamp calipers. Keep in case or wrap in soft cloth when not in use.
RA PD 87241
HOW NOT TO USE A MICROMETER
Lubrication
Oil threaded and moving parts and friction surfaces (firm joint
calipers) with preservative lubricating oil (special). Coat nonoperating surfaces with a film of preservative lubricating oil
(special).
Cleaning, Inspection, and Repair
1. Disassemble caliper and wash parts in dry cleaning solvent. Dry
with a clean, soft cloth.
29
TM 9-867
2. Inspect all threaded parts to be sure all dirt is removed. Scarcely
visible particles may cause uneven thread motion and binding.
3. Inspect parts to see if they are rusted, corroded, burred, bent,
or worn. Scour with crocus cloth to remove rust or corrosion.
Replace parts which are bent, broken, or worn.
4. Lubricate parts as instructed above, and reassemble caliper.
Repair Bent Firm Joint or Spring Caliper
If leg is bent, place caliper on soft metal block. Straighten bent leg
to original shape by tapping with brass hammer. Replace bent
adjusting screws.
RATCHET STOP------THIMBLE CAP
THREAD PLAY ADJUSTMENT NUT
FIXED NUT C
MICROMETER SCREW
-THIMBLE
-BARREL
-CLAMP
)
RING .
TYPICAL
MICROMETER
CALIPER
CUTAWAY VIEW
30
j
TM 9-867
Adjustment of Micrometer Caliper
To compensate for thread wear, screw thimble from barrel. Tighten
thread play adjustment nut on fixed nut a fraction of a turn at
a time. Test fit of micrometer screw in fixed nut. Repeat tightening
and test until operation is free from both binding and play.
NOTE: Some micrometers have an automatic spring-controlled
thread play adjustment.
Testing Micrometer
Caliper
1
Clean measuring faces with a soft cloth.
Examine faces after cleaning and remove any lint deposited by cleaning
cloth.
2
Measure length of micrometer test gage
of same length as minimum capacity of
micrometer. Micrometer should read its
exact minimum capacity. For 0-1 inch
micrometer, screw thimble down until
spindle contacts anvil. Do not force
thimble. Reading should be 0.000 inch.
3
Measure length of a micrometer test
gage of same length as maximum
capacity of micrometer. Micrometer
RA Pa 87243
should read its exact maximum capacity.
Check inside micrometers against outside micrometers or gage
blocks.
If in checking it is found that micrometers do not read correctly,
refer to proper authority for adjustment.
Never use inaccurate micrometers.
Misuses
Never use micrometers with dirty anvil and/or threads.
Dirt on micrometer anvil gives incorrect readings. Dirty threads
cause excessive wear and eventually inaccurate readings.
Do not carry micrometers in a pocket of work clothes, as dirt
from the pocket works into the threads.
Keep micrometers in a covered box on the job and wipe anvil
and spindle clean with a soft, slightly oiled rag each time after
using and before returning them to their places in the box. Keep
cover closed to protect micrometers from dirt and grinding dust.
835846 0 - 49 - 3
31
TM 9-867
-
I
WRONG
RIGHT
RA PD 87244
Do not check a part that is moving or rotating. Damage to the
micrometer and possible injury to the operator will result.
WRONG
RIGHT
RA PD 87245
Storage
Wrap in greaseproof wrapping and enclose in a covered box. Store
oughly and apply a film of preservative lubricating oil (medium).
Wrap in greaseproof wrapping and enclose in a covered box. Store
in a dry place.
32
TM 9-867
Section VIII
CHISELS
BLACKSMITH'S
HANDLED
COLD
CHISE
BLACKSMITH'S
HANDLED
HOT CHISEL
CUTTING EDGE
MACHINIST'S
CAPE
CHISEL
BEVEL
MACHINIST'S
DIAMOND
POINT CHISEL
SHOULDER
MACHINIST'S
COLD
CHISEL
SOCKET
WOODWORKERS CHISEL (BEVEL EDGE BLADE)
HANDLE
RA PD 87246
CARE (All Types)
Keep chisels properly ground, sharpened, and free from mushroom
head at all times. Scour off all rust or corrosion and protect metal
surfaces with a film of preservative lubricating oil (special) or
engine oil (SAE 10). Keep chisels in a rack or box designed to
protect cutting edges from contact with metal.
GRINDING WOODWORKER'S CHISEL
General
Grinding is necessary when cutting edge is nicked, when bevel is
worn too blunt to sharpen on an oilstone, or when bevel is rounded
out from incorrect sharpening. Before reshaping cutting edge of a
chisel by grinding, there are two important things to remember:
33
TM 9-867
1. Bevel may be slightly concave or perfectly straight. It must
never be rounded out.
BEVEL IS
CONCAVE OR
SHAPE OF
GRINDING
WHEEL
9
BEVEL IS
FLAT OR
PERFECTLY
STRAIGHT
BEVEL IS
ROUNDED OUT
BY IMPROPER
GRINDING OR
SHARPENING
RA PD
87247
2. Bevel should be about twice the thickness of chisel near cutting
edge.
_lifili
LENGTH OF BEVEL IS
APPROXIMATELY
TWICE THE THICKNESS
OF CHISEL
Iim
U·rl4dine
BEVEL IS TOO LONG
BUT MAY BE PREFERRED
WHEN CUTTING SOFT
WOOD. CUTTING EDGE WILL
NICK AND DULL EASILY
BEVEL IS TOO BLUNT.
CHISEL WILL NOT CUT
INTO WOOD EASILY.
IT IS HARD TO WHET
OR SHARPEN
IRC'PD 87248
Procedure
CAUTION: While grinding, keep chisel cool by frequently dipping
into water to prevent burning or softening of the steel.
1. Square cutting edge and remove nicks if necessary.
2. Adjust rest on grinder to position which will give correct bevel.
3. Reshape bevel by moving chisel from side to side to grind all
parts of bevel evenly and to keep grinding wheel true.
4. Check bevel to make sure it is straight across and at right angles
to sides of chisel.
RESHAPE
CHECK
NOTE: Special holding fixtures are available. Their use greatly
simplifies grinding of chisel type tools.
34
TM 9-867
SHARPENING WOODWORKER'S CHISEL
Whetting
Always whet chisel after grinding. Once chisel is ground, it can be
kept sharpened for a long time by whetting as often as necessary.
1. Clean oilstone and place enough oil on it to wet surface.
2. Place chisel on stone as shown in illustration to obtain correct
angle.
3. Hold chisel firmly and move
it back and forth along entire
length of stone.
CAUTION: Avoid wearing a
groove in stone. Move chisel
evenly over entire stone.
4. Place flat side of chisel on
stone as illustrated and remove
wire edge.
5. Repeat stoning of bevel and
flat until chisel is sharp.
RA PD 87250
Stropping
For an extremely keen edge, finish with a few strokes on a leather
strap, or by stropping first on one side and then on other on a
soft wood block.
SOFT WOOD BLOCK
_
STROP SIDES ALTERNATELY
TEN OR TWELVE TIMES
UNTIL WIRE EDGE IS
REMOVED
RA PD 87251
REPAIRING MUSHROOMED HEAD
(Woodworkers' Chisel)
MUSHROOMED HEAD
HANDLE
DOTTED LINE SHOWS
ORIGINAL SHAPE
RA PD 87252
35
TM 9-867
Chisel heads become battered or mushroomed after considerable
use. To make a permanent repair:
1. Remove handle from chisel. Saw handle off at point of contact
with head.
2. Turn end of handle down to about v%6 -inch diameter for about
3/8 inch.
3. Cut leather or fiber washers to fit snugly over tip cut on end
of handle. Be sure outside diameter of washers slightly exceeds
outside diameter of handle. Cut enough washers so their total thickness equals or slightly exceeds height of tip on end of handle.
RA PD
./
w
?
P87253~~~~~~87253
4. Glue washers onto end of handle. Clamp until glue dries.
5. Grind, sand, or cut washers down to conform to shape of handle.
REPLACING HANDLE
(Woodworkers' Chisel)
1. Pull old handle from socket. If handle is broken off in socket,
drill it out.
2. Shape end of new handle until it is a snug fit in socket.
3. Place blade in soft-jawed vise and tap handle to seat in socket.
MAINTENANCE OF BLACKSMITHS' AND
MACHINISTS' CHISELS
Grinding
The cutting angle of a chisel is
determined according to the hardness and toughness of the materials being cut. An included cutting edge angle-of 70 degrees does
well for most work. While chisels
used on hard or tough metal require greater strength backing up
the cutting edge, an angle up to
90 degrees may be used for this
purpose. The cutting angle can be
decreased somewhat from 70 degrees for cutting softer metals.
ANGLE "A" IS
USUALLY 700.
IT IS SOMETIMES
GROUND° AT
UP TO 90
FOR
CUTTING
EDGE
SLIGHTLY
CURVED
CUTTING EXTREMELY
HARD METAL
RA PD 87254
36
TM 9-867
Set rest to secure desired bevel angle. Move chisel head from side
to side a little during grinding to slightly curve cutting edge. Turn
chisel over to grind other bevel. Keep bevels same size or cutting
edge will not be centered. Dip chisel frequently in water to preserve temper. NOTE: After several grindings, cutting end of chisel
may be too thick. Such chisels can be heated and reforged, tempered, and ground.
Hardening and Tempering
Machinists' Chisels
Heat whole chisel to cherry red in a gas furnace or charcoal fire.
Grasp chisel in center with tongs. Dip cutting end in clear, cold
water to a depth of about 1Y4 inch. Turn chisel over and dip head
end about 1 inch. Quickly polish hardened ends with a file, or
aluminum oxide abrasive cloth. Watch color return from heated
center section of chisel to ends. Redip cutting end every time end
becomes purple. Redip head end every time it becomes blue. When
red disappears from chisel, dip whole tool.
CHISEL
TONGS
I
WATER IN
WELL FILLED 1
CONTAINER
.
GRASP CHERRY RED
CHISEL IN CENTER
AND DIP STRAIGHT
DOWN
0
RA PD 87255
Removing Mushroomed End From
Machinists' Chisels
It is dangerous
cutting chisel
roomed head.
original shape.
after removing
to use a metalwith a mushGrind head to
Harden chisel
mushroom.
RA PD
87256
Replacing Handles on Blacksmiths' Chisels
Follow procedure given under Hammers, Mallets, Mauls, and
Sledges (section 12).
Common Misuses and Abuses
Drawing temper or burning during sharpening.
Exerting too much pressure against the wheel during sharpening
37
TM 9-867
causes excess heat at the cutting edge of the chisel. When and if the
temperature of the cutting edge goes above the temper drawing
heat, it causes the cutting edge to lose the hardness required for
cutting edges. If the cutting edge of the chisel colors to blue or pale
blue, the loss of temper has taken place. Exerting light pressure and
frequent cooling in water while grinding is the proper preventive
maintenance. If the cutting edge becomes too soft due to too much
heat in grinding or too frequent grinding, the chisel must be hardened and the temper drawn in order to restore the proper hardness.
Storage (All Types of Chisels)
Apply rust preventive compound (thin film) to chisels before storage and protect cutting edge from contact with metal or abrasives.
Store in a dry place. After removal from storage, wash metal parts
with dry cleaning solvent to remove rust preventive compound.
38
TM 9-867
Section IX
CLAMPS
TOOLMAKER'S
CLAMP
HYDRAULIC BRAKE CLAMP
RA PD 87257
MAINTENANCE
General-All Clamps
These are relatively heavy-duty but simple tools. Maintenance
requirements are few:
Keep screws lubricated with small quantity of preventive lubricating oil (special) or engine oil (SAE 10). Excessive lubricant
interferes with use of tool. Keep metal surfaces free of rust. Scour
off rust or corrosion with crocus cloth or aluminum oxide abrasive
cloth. Coat surfaces with preservative lubricating oil (special) or
engine oil (SAE 10).
Varnish hardwood jaws of hand screw clamps whenever finish
becomes damaged extensively enough to leave wood without protective coating.
Replace all parts broken or damaged beyond repair.
LUBRICATE
SCREWS
REMOVE
RUST
VARNISH
WOOD
RA PD 87258
39
TM 9-867
Replace C-Clamp Screw or Jaw
1. Pry open crimped portion of swivel head and remove head from
ball on end of screw. Turn the screw out of iaw.
C-CLAMP
DISASSEMBLED
RA PD 87259
2. Using new parts as needed, turn the screw into position through
its boss at end of jaw. Slip swivel head onto ball on end of screw
and crimp head sufficiently to hold it on ball.
Replace Handle on Hand Screw Clamp
or Toolmaker's Clamp
File off peened ends of pin which attaches handle to screw. Drive
out pin. Unscrew or drive handle from screw. Screw new handle in
position on screw with pinholes in handle and in screw alined. Tap
in and peen pin.
Replace Jaw, Screw or Insert on
Hand Screw Clamp or Toolmaker's Clamp
1. Remove handles in accordance with instructions above. Turn
both screws from the two jaws. Lift inserts (if any) from jaws.
PIN
-JAW
JAWINSERT
iHANDLE
t
HANDLEA
SCREWS
A
_
gf~-:90MU
3----
PIN
INSERT
RA PD 87260
2. Using new parts as necessary, place inserts (if any) in position
in jaws. Turn both screws into position in the two jaws. Install
handles on screws.
40
TM 9-867
Common Misuses and Abuses
Do not use a wrench or bar in tightening clamps. Too much
pressure may warp, bend, or break them. Tighten clamps by hand.
When applying great pressure, observe clamps for indication of
undue strain.
WRONG
RIGHT
RA PD 87261
Do not cock clamp to tighten. This procedure may warp, bend,
or break clamps. Keep jaws parallel.
RIGHT
WRONG
RA PD
87262
Storage (All Clamps)
Coat clamps with rust preventive compound (thin film) and store
in a dry place. After removal from storage, wash metal parts with
dry cleaning solvent to remove rust preventive compound.
41
TM 9-867
Section X
DIVIDERS
SPRING DIVIDERS
WING DIVIDERS
RA PD 87263
MAINTENANCE
General
Wipe fingerprints and moisture from dividers after use to prevent
rusting or corroding. Keep in case or wrap in soft cloth when not
in use.
Lubrication
Oil threads, pivots, and other surfaces sparingly with preservative
lubricating oil (special).
Sharpening Points
Sharpen divider points with a
small oilstone moistened with
light oil. Keep points toward
inside of legs so points will
meet when dividers close. Hold
dividers stationary and stroke
with stone. Give stone a slight
rotating movement to prevent
flat spots.
RA PD 87264
Installing Pivot on
Spring Dividers
Insert a block between legs
above screw. Squeeze legs together to spread spring.
42
TM 9-867
Common Misuses and Abuses
Do not use dividers as an awl or for any other purpose than scribing
arcs or circles, or for checking measurements. Dividers are precision
tools and must be handled and used carefully to preserve their
accuracy.
~~~~~~RA
PD
WRONG
87266
Do not lay dividers on bench when not in use. They may be
damaged by other tools. Keep them in case or wrapped in cloth
and stored in a safe place.
WRONG
RIGHT
RA PD
87267
Storage
Apply rust preventive compound (thin film). To protect the points,
insert them into small corks, small short twigs, or soft wood block.
Store in a dry place. Upon removal from storage, wash with dry
cleaning solvent to remove rust preventive compound.
43
TM 9-867
Section XI
FILES AND RASPS
-HANDLE
TANG
FERRULE
.-
HEEL
EDGE
FACE
FLAT
V_•
POINT
Care
ROUND
TAPER
-
HALF
RA PD
ROUND
87268
MrAINTENANCE
Preserve sharpness of files. Keep them in a rack. If necessary to
carry files in a tool box, wrap them individually in cloth or paper.
Keep files dry to prevent rusting. Do not use rust preventive compound. Do not abuse files. They are brittle and extremely dangerous
if hammered or used as pry bars.
Installing Handle
CAUTION: It is dangerous to use a file without a handle.
1. Select handle to fit tang. If necessary to use handle having hole too
small for tang, heat same size tang
of an old file and insert in handle to
burn hole to proper size (snug fit).
2. Wet tang of file and insert it in handle. Tap back end of handle on a flat
surface until file is properly seated.
Do not hammer file into the handle.
NOTE: Several types of "screw-on"
handles are available. If using handle
of this type, install as directed by
handle manufacturer.
_
RA PD 87269
44
TM 9-867
Removing Handle
Hold file with left hand. Hold
handle with right hand. Pull file
from handle while rapping ferrule
end of handle against edge of
bench.
'!!!!/
NOTE: If removing "screw-on"
type handle, remove in accordance with handle manufacturer's
instructions.
-
RAPD
87270
Cleaning Files
1. The cutting action of a file
produces small particles or chips
called filings. These particles frequently wedge between the teeth
of file and impair the free cutting
action. Frequent cleaning is
necessary to obtain maximum
efficiency of file.
FILINGS
~WORK
RA PD 87271
BRU
MOTION PARAL
TO TEETH
2. Brush filings from between
teeth of file with wire brush. Push
brush in a direction parallel with
teeth.
RA PD
· " ~~~~
87272
· *~~
3. Remove remaining particles from teeth by using a narrow strip
of soft metal such as brass or copper. A soft metal will not damage
teeth.
CLEANING PIN
(SOFT METAL)
45
TM 9-867
Common Misuses and Abuses
Do not strike file against vise or other object to clean it. This
practice ruins file teeth and may break file. There is danger from
flying particles if file breaks. Clean file with a file card and pin.
WRONG
RIGHT
RA PD
87274
Never use a file without a handle. It is dangerous. Install handle
before using file for any job, no matter how small.
RIGHT
,k-E:-
RA PD
87275
Do not use excessive pressure while filing. This results in clogging
file and stripping teeth. Use a long, steady, uniform stroke. Hold
handle with right hand. Hold end of file between thumb and first
finger of left hand.
\\~~~~~
,-
WRONG
RIGHT
RA PD
87276
Storage
Be sure files and rasps are clean and dry. Do not use lubricants or
rust preventive compounds. Wrap them individually in waterproof
barrier wrapping paper. Place in racks or box in a manner which
will make it impossible for faces or edges of files to contact each
other.
46
TM 9-867
Section XII
HAMMERS, MALLETS, MAULS, and SLEDGES
HAMMER
BALL-PEEN
HAMMER
HAMMER
SOFT METAL OR
PLASTIC HAMMER
DING WEIGHT
HAMMER
BELL-FACED CLAW HAMMER
PLAIN FACED
CLAW HAMMER
WOODEN
MALLET
RIVETING
HAMMER
DOUBLE FACE
SLEDGE
TRIMMER'S
HAMMER
CROSS PEEN
SLEDGE
STRAIGHT PEEN
SLEDGE
RUBBER
MALLET
RA PD 87277
CAI tE OF HEADS
General
Prevent rust formation by carefully wiping steel hammer heads dry
after exposure to moisture. When it is known in advance that tool
will be exposed to moisture, spread a film of preservative lubricating
oil (special) or engine oil (SAE 10) over head.
835846 0 - 49 - 4
47
TM 9-867
Frequently inspect hammer type tools to see if handle is tight
in head and to see if face is in satisfactory condition.
Replacing Handle
1. Remove old handle from
head. If handle is tight, saw
off old handle next to neck of
hammer head. Do not saw the
handle off so close to the head
that the saw teeth will touch
the head while sawing, thus
damaging the set of the saw.
A hacksaw may also be used.
11I
2. Drill a hole in old handle
as illustrated.
3. Drive old handle from head
and secure wedges. (Note position of wedges.)
4. Shape new handle to fit
head. Use rasp or spoke shave.
-
5. Insert new handle to head
to determine fit.
'eo
6. Assemble for tight fit by
striking end of handle with
mallet to seat head firmly on
handle.
RA PD 87278
48
TM 9-867
7. Check results to determine if
handle fits properly.
= --
8. Saw off the projecting portion of handle close to hammer
head and cut slits for wedges.
Avoid having saw teeth touch
the head during sawing.
.1
anmr-
9. Drive wedges into handle. If
wooden wedges are used, replace old wedges or make new
ones from straight grain soft
wood.
RA PD 87279
10. File or grind end of handle even with head. Use wood rasp if
wooden wedges are used. Grinding may be employed if metal
wedges are used.
RA PD 87280
Tightening Handle
If wedge comes loose, remove it and install larger wedge. If wedge
remains tight in handle, but handle loosens, drive thin hardwood or
iron wedge into handle beside original wedge. A loose handle can be
temporarily repaired by soaking in water. If unable to tighten,
replace handle.
Grinding Face
Incorrect or abusive use of hammer type tools frequently results in
uneven face wear. To reshape worn faces:
49
TM 9-867
1
Determine if face should be plain
or bell shaped by examining unworn portion of face or by comparing with unworn tool of same
WORN
FACE
type.
2
Grind face to original shape. Frequently immerse head in water
to prevent burning. Do not remove more stock than necessary.
RESTORED
3
On mallet type tools, grind equal
amount of material from both
faces to preserve balance.
FACE
RA PD 87281
Common Misuses
Do not strike a hardened steel surface with a hammer.
This misuse is a serious safety hazard. Small pieces of sharp,
hardened steel break from the hammer and also from the hardened
steel. This has been responsible for many serious eye injuries. It
may also cause damage to the work and/or the hammer.
Use a soft hammer in striking any hardened steel. If a soft
hammer is not available, place a piece of copper, brass, fiber, or
wood on the hardened steel. Strike the soft material and not the
hardened steel.
Storage
Coat steel heads with rust preventive compound (thin film) and
store in a dry place. Upon removal from storage, wash metal parts
with dry cleaning solvent to remove rust preventive compound.
50
TM 9-867
Section XIII
HAND GRINDERS
1L
ENCLOSED
GEAR CASE
(OIL TIGHT)
RA PD 87282
CLEANING
Drain lubricant from enclosed type gear cases. Flush out with
dry cleaning solvent. Drain. gear case completely after flushing.
Refill with correct grade of lubricant as specified.
Wash exterior surfaces and open type gears with dry cleaning
solvent. Scour corrosion from surfaces with crocus cloth.
51
TM 9-867
LUBRICATION
Lubricate grinders in accordance with following chart:
PART
LUBRICATION
PERIOD
PERIOD
LUBRICANT
LUBRICANT
Enclosed gear cases
(oiltight)
Weekly
OIL, engine, SAE 30
Enclosed gear cases
(grease type)
Weekly
GREASE, general purpose,
No. 0
Open gears
Daily
Handle bearings
Daily
Pivot pins
Daily
OIL, engine, SAE 10, or OIL,
lubricating, preservative,
special
OIL, lubricating, preservative, special
Exterior nonwearing
surfaces
Common Misuses
Careless handling. Tools of this type will not stand rough handling
and continue to operate satisfactorily.
Do not strain working parts beyond capacity. Do not throw into
box loosely with other tools.
WRONG
RGHT
RA PD 87283
Storage
For indefinite storage, drain lubricants and wash tool in dry cleaning
solvent. Dry thoroughly, relubricate and fill gear cases, and spread
rust preventive compound (thin film) over all parts. Wire small
attaching parts to valve grinders to prevent their loss. Store in a dry
place. Mobile field units should check tightness of all screws and
nuts before and after storing, and should wrap sufficiently to keep
out all dust and to protect grinder.
Upon removal from prolonged storage, wash rust preventive compound from grinder with dry cleaning solvent.
52
TM 9-867
Section XIV
HATCHETS, AXES, MATTOCKS, ADZES, and SHOVELS
BROAD HATCHET
4
MATTOCK
SHIP ADZE
CARPENTER'S ADZE
SHOVEL
RA PD 87284
GRINDING
Hatchets and Axes
REMOVE NICKS
BY GRINDING
1
Remove nicks by holding horizontally against abrasive wheel.
Move back and forth across
stone.
2
Grind cutting edge of hatchet
to bevel indicated. Grind ax as
described below. Frequently cool
in water to preserve temper.
Move from side to side across
face of grinding wheel.
53
RA PD 87285
TM 9-867
Adzes
Remove handle
and grind to
CORRECT HATCHET BEVELS
same level as when grinding a
hatchet to hew to a line. Bevel
on handle side only.
Mattocks
Follow procedure for grinding
hatchet, and grind to original
bevel.
Correct Ax Bevels
Careless grinding will ruin any
RA PD
ax by either destroying the
87286
temper through heat caused by
friction, or by making the edge
FOR GENERAL
FOR HEWING
TO A LINE
USE
so thin it will not stand up under
the force of a swinging blow. Do not use a high speed dry grinding
wheel. An ax ground on a dry wheel will surely be ruined. Grind
slowly on a wheel kept very wet.
When regrinding, start to grind from 2 to 3 inches back from the
cutting edge and grind to about /2 inch from edge. Work for fanshape effect, leaving reinforcement at corners adequate for sufficient strength. Then "roll off" on a convex bevel as shown in the
cross-section illustration of an ax
CORRECT AXE BEVELS
bit at right. This illustration is
exact gage "life size" and shape
__
of properly ground cutting edge.
GROUND WITH
with
Remove all .scratches
CONVEX
whetstone or hone. A scratch on
_
_
highly tempered steel will freRIGHT
quently cause material to break
where it is scratchedr
-
GROUND
CONCAVE
_
_
_
GROUND
STRAIGHT
WRONG
WRONG
RA PD 87287
This illustration shows the cut
ting edge ground with a long
straight bevel, better than the
concave bevel, but still without
sufficient reinforcement back of
the edge.
The illustration above shows
the most frequent mistake in
regrinding. It is ground concave-the wrong way-leaving
insufficient support behind the
edge to withstand any ordinary
blow. It will break very easily.
54
TM 9-867
Shovels
NOTE: If shovel is bent, hammer it straight on a flat block or
anvil before grinding. Do not use
heat while straightening a shovel.
Hold shovel in a horizontal position against an abrasive wheel
and grind to outline indicated in
sketch. Grind blunt bevel along
cutting edge. Cool shovel in
water at frequent intervals during
grinding to preserve temper.
CORRECT
CUTTING
EDGE
BEVEL
PA PD 87288
SHARPENING
`
Straight-edged
Hatchet Type Tool
Grasp tool as indicated in sketch and
place on a lightly oiled oilstone. Tilt
tool so bevel lies flat on stone. Exert
slight pressure on tool. Hold right
RA PD 87290
wrist rigid (no sidewise twist), and
move tool back and forth on stone a few times. If tool is ground
with a double bevel, turn tool over and repeat operation.
Curved-edged
Hatchet Type Tool
STONE
1. Hold tool stationary. Place
stone flat on bevel. Apply light
pressure and move stone with a
circular motion.
2. Place stone on other bevel (if
any) and repeat operation. If
only one bevel is used, place
stone flat on other side of tool
head and remove wire edge with
a circular motion.
55
CUTTING
BEVEL
a
EDGE
DOUBLE BEVEL
SINGLE BEVEL
RA PD 8729
TM 9-867
"
I
RA PD 87292
Shovels
Place smooth file flat on bevel as illustrated. Apply pressure to
file on forward stroke. Lift file clear of shovel on back stroke.
REPLACING HANDLES
Hatchets, Axes, and Adzes
Procedure is identical with that given for hammers, mallets, mauls,
and sledges (section 12).
Mattocks
Tap butt
from butt
slide into
to tighten
of handle on a solid surface to loosen head. Slide head
of handle. Insert new handle, butt first, through head and
approximate position. Rap head end of handle on floor
head on handle.
Shovels
Cut or grind off peened heads of rivets which attach shovel to
handle. Drive out rivets and pull handle from shovel. Insert new
handle into position in shovel. Drill rivet holes through handle.
Insert and peen rivets.
Common Misuses (Hatchets, Axes,
Mattocks, and Adzes)
Do not strike heavy blows when tool is very cold. Breakage may
result because frost makes steel brittle. Warm ax before using in
cold weather.
WRONG
_i= -e I
RA PD 87293
56
TM 9-867
Do not use tools as mauls or wedges. Breakage across or under
the eye often results. Use tools only for use intended.
RIGHT
WRONG
RA PD 87294
Common Misuses (Shovels)
Do not use shovel as a pry bar. Handles break easily. Avoid undue
strain on handle.
AL
WRONG
RA PD 87295
Never return shovel to storage without proper cleaning. Dirt
will harden and shovel will rust. Always clean shovels thoroughly
after using.
Storage
Coat metal surfaces with rust preventive compound (thin film) and
store in a dry place in racks or boxes with cutting edges protected.
Upon removal from storage, wash rust preventive compound from
metal parts with dry cleaning solvent.
57
TM 9-867
Section XV.
HYDROMETERS
Cleaning
Wash body and float with soap
and water. Use care when washing float to keep from injuring
markings. Battery acid deposits
which do not yield to soap and
water, can be removed with a
solution of hot water and soda.
Care in Use
Provide a well-protected container positioned in a handy
bench.
place
near
battery
Handle with extreme care and
replace to storage position when
not in use. Clean grease from
bulb and tip with carbon tetrachloride or soap and water.
Flush with water and wipe dry.
III
Storage
Store in a cool place protecte, d
from direct sunlight. Wrap float i:n
lens tissue paper and pack hydrom
eter securely to prevent damage
58I
RA PD
87297
TM 9-867
Section XVI
KNIVES
FOLDING HANDLE DRAW KNIFE
RA PD 87298
GRINDING
NOTE: Do not grind small knives such as saddler's or electrician's
knives except to shape a broken blade. Sharpen them on an oilstone.
Putty Knife
Hold
knife
perpendicularly
against edge of abrasive wheel
to "square up" worn blade. Dip
in water often to preserve
temper. Keep blade at right
angles to surface of wheel and
TOP VIEW
SIDE VIEW
move from side to side during
grinding.
Do not grind away more stock
than necessary. Remove wire
edge and smooth end on oilstone.
59
TM 9-867
Draw Knife
A draw knife may be ground with a single bevel or a double bevel.
Grind to same bevel as originally ground as revealed by inspection
of unworn portions at ends of cutting edge. Bevels may be straight
or slightly concave. Never grind bevels convex. Make bevel approximately twice the width of blade at point where bevel starts.
Grinding procedure follows:
1. Adjust rest at midpoint of
wheel. Run knife back and forth
full length of blade maintaining
original shape, until nicks are
removed.
2. Adjust rest toward top of
wheel to provide correct bevel.
Run knife back and forth full
length of blade until bevel is
secured.
3. If double bevel is sought, turn
knife over and grind second bevel.
CAUTION: Be sure to dip knife
in water frequently to prevent
burning and subsequent loss of
temper.
68
RIGHT
STRAIGHT
BEVEL
RIGHT
CONCAVE
BEVEL
WRONG
CONVEX
BEVEL
CORRECT BEVEL LENGTH
RA PD 87300
RESTORE BEVEL
RA PD
87301
SHARPENING
Small Knives
Sharpen on a medium or fine oilstone moistened with a few drops
of oil. Apply blade to stone with
back tilted slightly from stone. Hold
blade obliquely across face of stone
and rub briskly back and forth.
Repeat on other side of blade. Remove wire edge by stropping on a
piece of leather or canvas.
60
^ itiC? A_;:::y'DE
$
f
RA PD 87302
TM 9-867
Draw Knife
Place a medium or fine oilstone on a block sufficiently high to
cause draw knife's handles to clear bench. Moisten oilstone with a
few drops of clean light oil. Place knife blade on stone and tilt
knife so bevel lies flat on stone. Rub blade on stone in a circular
motion so entire length of bevel contacts stone. If blade has a
double bevel, turn knife over and repeat operation. Remove wire
edge by stropping on a piece of leather or canvas.
RA PD 87303
Common Misuses
Do not use tool with prying or lever action.
Blade ends and/or sharp thin edges will break if strained beyond
breaking point.
Undue straining will loosen rivets and joints.
Handle carefully and use only for purposes intended.
Storage
Coat all metal parts of knives with rust preventive compound
(thin film) at time of storing. Store in a dry place with cutting
edges protected from contact with metals or abrasives. Upon
removal from storage, wash metal parts with dry cleaning solvent
to remove rust preventive compound.
61
TM 9-867
Section XVII
LEVELS
5
PLUMB LEVEL
STRIDING LEVEL
RA PD 87304
Test
CARE OF LEVELS
1. Place level on a true horizontal surface and note level indication.
Reverse level end for end. If bubble appears on one side of hairline
on first reading and on other side for second reading, level is out
of adjustment.
A
B
A I
B
1. LEVEL TEST
F
A
2.
PLUMB
TEST
2. Place plumb level against a
true vertical -surface and note
plumb reading. Twist level onehalf turn about its vertical axis
and again take reading. If bubble
appears on opposite sides of hairline in the two readings, plumb
level is out of adjustment.
62
RA PD
87305
TM 9-867
Adjustment
ADJUSTABLE LEVELS (METAL OR WOOD CONSTRUCTION): Turn adjustment screw or nut to move spirit tube in
direction indicated by test. Repeat adjustment and test until
bubble centers on cross hair (single hairline level) or until bubble
is centered between cross hairs (double hairline level).
NONADJUSTABLE METAL-FRAMED LEVELS: Remove screw,
bolt or rivet which attaches low end (as revealed by tests) of spirit
tube to frame. Shim up low end of tube with shim stock and
attach tube to frame. Test level. Repeat adjustment and test
until fault is corrected.
NONADJUSTABLE WOOD-FRAMED LEVELS: Carefully dig out
plaster of paris bed which attaches spirit tube to frame. Place level
on a true horizontal or vertical surface (depending on whether
level or plumb spirit tube is being adjusted). Using fine calcined
gypsum for a tube bed, position spirit tube so bubble centers on
hairline. Allow gypsum to set before moving level.
RA PD 87306
Common Misuses
Rough handling. A level is a precision tool, therefore it must be
used and handled with extreme care to preserve its accuracy. Do
not drop. Do not strike. Place level carefully against work.
Storage
Coat metal parts with rust preventive compound (thin film) at
time of storage. Place tool in a rack or box which will protect it
from accidental breakage. Store in a dry place. Upon removal from
storage wash metal parts with dry cleaning solvent to remove
rust preventive compound.
835846 0 - 49 - 5
63
TM 9-867
Section XVIII
NIPPERS AND PLIERS
!0
TYPICAL
NIPPERS
A
TIRE CHAIN
REPAIR PLIERS
t
ADJUSTABLE
COMBINATION
PLIERS
HALF ROUNDNOSE PLIERS
FLAT-NOSED
PLIERS
BRAKE SPRING PLIERS
DIAGONAL CUTTING NIPPERS OR PLIERS
RA PD 87307
ROUND-NOSED PLIERS
MAINTENANCE
Grinding and Sharpening
NOTE: Many modern side cutting pliers and nearly all nippers
are designed so they can be reground. Some older models will not
close if material is ground from cutting edges.
Examine pliers to see if design will permit them to close completely if material is ground from cutting edges. Do not attempt
to sharpen pliers not designed to be ground.
Grind cutting edges so ground bevel is at approximately right
angles with inside machined bevel. Grind same amount of stock
from both jaws but no more than necessary to remove nicks. Cool
often in water to preserve temper.
64
TM 9-867
CORRECTLY GROUND CUTTING EDGES
NOTE: Jaws on some pliers will not open wide enough to permit
grinding. On such pliers, press out recessed taper pin or remove
special bolt and nut which attach the two halves of pliers together
and separate jaws for grinding. Peen pin well when assembling
pliers which are pinned together.
Cleaning
Wash pliers in dry cleaning solvent and wipe dry with a clean
cloth. Clean dirt from serrated jaw faces with a wire brush. When
completely dry, lubricate pivot pin with one or two drops of
preservative lubricating oil (special) or engine oil (SAE 10).
Renewing Jaw Face Serrations
Place the pliers in a vise protected
with soft jaws and renew serration
with a four- or five-inch threecornered file. If the jaws of the
pliers can be separated and the
mechanic has access to a small surface grinder, new serrations can be
ground. Diamond dress a narrow
wheel to an included angle of 60
RA PD 87309
degrees (30 degrees on each side of centerline) and grind the
serrations with each jaw held separately in a grinding vise.
GRINDING WHEEL
65
TM 9-867
Common Misuses
Do not use pliers on a nut.
This batters nut and plier jaw
serrations unnecessarily. Use a
wrench on nuts.
WRONG
Do not use pliers as a pry bar.
Handles may bend or break.
Use tools only for purpose for
which they are designed.
WRONG
RA PD 87311
Storage
At time of storage, apply rust preventive compound (thin film).
Store in a dry place. Upon removal from storage, wash with dry
cleaning solvent to remove rust preventive compound.
66
TM 9-867
Section XIX
PLANES
GRINDING PLANE IRONS
General
Irons must be ground when cutting edge is nicked, when bevel is
worn too blunt, when bevel is rounded out, or when cutting edge
is worn to improper shape.
1. Cutting edges should be straight on smooth and block plane
irons, slightly curved on jack plane irons, and very slightly curved
on fore plane irons.
SMOOTH OR
BLOCK PLANE IRON
90X1 32 IN.0
,
ROUND
CORNERS
SLIGHTLY
t
CUTTING EDGE
PERFECTLY
STRAIGHT
JACK PLANE
IRON
FORE PLANE
IRON
t
CUTTING EDGE VERY
SLIGHTLY CURVED
(1/32 IN. BULGE)
67
i
90
1 16 IN. 90'
CUTTING EDGE CURVED
SLIGHTLY
(1/16 IN. BULGE)
RA PD 87313
TM 9-867
2. Bevel may be straight or slightly concave. It must never be
rounded out.
RIGHT
RIGHT
WRONG
BEVEL IS
CONCAVE OR
SHAPE OF
ABRASIVE
WHEEL
BEVEL IS
FLAT OR
PERFECTLY
STRAIGHT
BEVEL IS
ROUNDED OUT
BY INCORRECT
GRINDING OR
SHARPENING
RA PD 87314
3. Bevel should be about twice the thickness of iron near cutting
edge.
RIGHT
WRONG
WRONG
RA PD 87315
Procedure
CAUTION: While grinding, keep plane bit cool by frequently
dipping into water to prevent burning or softening of the steel.
Keep the fingers near the grinding edge while grinding to feel and
determine if plane iron is becoming too hot.
1. Square cutting edge, and remove nicks as necessary.
2. Adjust rest on grinder to a position which will give correct bevel.
3. Grind by moving iron from side to side to grind all parts of
bevel evenly, and square with the edges.
SQUARE
RESHAPE
ADJUST
REST
CHECK
TOP
VIEW
RA PD 87316
NOTE: Special holding devices are available for sharpening plane
bits. Their use simplifies the grinding.
SHARPENING PLANE IRONS
General
Always sharpen iron after grinding. During use of plane, sharpen
iron as often as necessary to keep a keen edge.
68
TM 9-867
Procedure
1. Grasp iron with both hands, palms downward. Place iron bevel
on lightly oiled stone with iron at bevel angle.
2. Apply light pressure to iron and rub back and forth over surface
of stone. Do not alter angle of iron to stone during process. Round
off corners enough to allow for depth of cut.
3. After whetting bevel side, turn iron over and hold perfectly flat
on stone. Give it two or three strokes to remove wire edge.
BEVEL
FLAT ON
STONE
WHETTING BEVEL
REMOVING WIRE EDGE
RA PD 87317
Regrinding Chip Cap
The chip cap is made of soft steel and the sharp edge is easily
dented or marred, thus requiring regrinding.
1. Separate the chip cap and plane iron and remove the chip cap
screw.
2. Grind the lower surface of the curved end on the side of a
grinding wheel.
_ _,
::
, i .<a 13
JTOP VIEW
END VIEW
RA P 87310
RA PD 87318
69
TM 9-867
3. Grind only as required to remove nicks.
4. Finish grind surface, and remove wire edge on an oilstone.
REMOVING WIRE EDGE
ABOUT 100
$-~'
ALTERNATE
/
FSHING
SURFACE
RA PD 87319
SETTING IRON
(Jack, Fore, and Smooth Planes)
General
Jack, fore, and smooth planes have
double plane irons. A chip cap is
secured to iron by a set screw. This
chip cap breaks the shaving as soon
as possible after it is cut. Depth of cut
is regulated by a depth screw. Set chip
cap back farther for a coarse chip or
shaving than for a fine one. Never
DOUBLE
PLANE IRtN
IRON
CHP CAP
allow chip cap corners to extend beyondHIP
cutting edge of plane iron; it must
always be back of cutting edge. A block
plane, having a single plane iron, has
CAP
RA PD 87320
no chip cap.
Procedure
1. Test fit of chip cap on iron. It must fit without gapping to
prevent shavings from forcing themselves between chip cap and
iron. If not a close fit, sharpen chip cap on an oilstone. Hold chip
cap so as to preserve original angle while sharpening.
2. Enter cap set screw into slot in iron. Adjust cap to /4 inch
from cutting edge of iron, and parallel with cutting edge. Tighten
set screw.
3. Adjust "set" (distance between cutting edge of iron and edge
of chip cap) by lightly tapping end of blade opposite cutting edge.
Proper sets are:
Type of Plane
Jack plane
Fore plane
Smooth plane
To Work
Soft Wood
To Work Hard or
Crossgrained Wood
1/6 in.
1/32 to 1/64 in.
'16 in.
1/32 in.
1/32 to 1/64 in.
1/32 to 1/6
4 in.
70
TM 9-867
ADJUSTING FROG
General
Frogs must be set square with plane sides and set forward with
sufficient clearance for chips to pass through without clogging.
FROG
RA PD 87321
Common Misuses to Avoid
Never lay plane face down. The blade may be nicked or dulled.
Always lay plane on edge when not in use.
RIGHT
RA PD
87322
Do not plane with grain of wood sloping down. The wood is likely
to tear and jam the plane. Always have grain of wood sloping
upward in direction of planing stroke.
RIGHT
WRONG
71
RA PD 87323
TM 9-867
Do not plane "head on." This practice quickly dulls the iron.
Place plane on wood at a slight lateral angle.
-
WRONG
'
RA PD
87324
RIGHT
Do not drag blade on wood on return stroke. This dulls the blade.
Tilt plane at an angle sufficient to cause blade to clear the work,
or lift plane completely.
I
WRONG
RIGHT
RA PD 87325
Do not attempt to do work with the wrong type plane. Such
procedure is wasteful of material, time, and energy. Use planes
for purposes indicated in following table:
Plane
Use
Remarks
Fore
plane
To true surface or
edge o lumber for
accurate work,
Hold plane firmly, right hand
on handle, left hand on knob.
Smooth
plane
To smooth rough
surfaces where
straight edges and
sides are not required.
Hold plane firmly, right hand
on handle, left hand on knob.
Block
plane
To make close joints,
to cut across the
grain or edges of
small lumber.
Use with one hand. Make light
cuts with short strokes toward
center of work. Do not run over
edge of work.
Jack
plane
A substitute for fore
or smooth plane.
Does not do as precise work.
Hold plane firmly, right hand
on handle, left hand on knob.
72
TM 9-867
Lubrication
Keep irons and screw threads coated with a thin film of preservative lubricating oil (special).
Storage
Plane irons should always be withdrawn fully into the plane bed
when tool is stored. Before storing, coat all metal parts of planes
with rust preventive compound (thin film). Store planes in boxes
or in racks in a manner to protect cutting edges of irons from
contact with wood, metals, or abrasives. Store in a dry place. Upon
removal from storage, wash metal parts with dry cleaning solvent
to remove rust preventive compound.
73
TM 9-867
Section XX
PUNCHES
TAPER PUNCH
HOLLOW PUNCH
PRICK PUNCH
CENTER PUNCH
PIN PUNCH
9RA
PD 87326
GRINDING AND SHAPING
Blunt End Punches
Grind pin punch, taper punch, or other blunt end punch so end
is perfectly flat and at right angles to centerline of punch.
RIGHT
END IS FLAT
AND AT
RIGHT ANGLE
TO PUNCH
AXIS
WRONG
END IS FLAT
BUT NOT AT
RIGHT ANGLE
TO PUNCH
WRONG
END IS
ROUNDED
OR BULGED
AXIS
WRONG
END IS
HOLLOWED
OUT OR
CURVED
-
INWARD
1. Set rest horizontal and at center
of grinding wheel.
2. Start wheel and feed punch into
grinding surface of wheel at right
angles to surface.
3. Twist punch during grinding to
get flat end on punch.
4. Cool punch frequently in water
to preserve temper.
5. Do not grind away more metal
than necessary to get a satisfactory
end.
74
)
RA PD 87327
TM 9-867
Cone-pointed Punches
Center punches and prick punches are ground to cone points.
Correct point angle for center punches is about 90 degrees. Right
point angle for prick punch is approximately 30 degrees. These
angles may be altered for special work.
~300 \
....
CENTER PUNCH
900
PRICK PUNCH
RA PD 87328
RA PD 87329
Correct Punch Point Angles
Adjust rest so punch meets face
of wheel at desired angle (see
illustration). Rotate punch during
grinding to make point symmetrical. Dip punch in water at frequent intervals to avoid "burning."
Do not grind away more material
than necessary to secure satisfac-
RA PD 87330
tory point.
Repairing Mushroomed Head
Grind to original shape. Always
temper punch after repairing
mushroomed head or it will quick-
RA PD 87331
ly mushroom again.
Tempering
Punches must be hardened and tempered if point has been ground
back past hardened section, if punch has been heated, or if mushroomed head has been removed. Procedure for hardening and
tempering is exactly like that described for machinist's chisels
(section 8).
Common Misuses
to Avoid
Never use a punch which
has a mushroomed head.
There is danger of injury from flying pieces.
Grind head to original
WRONG
RA PD
shape and temper punch
87332
before using.
75
X
RIGHT
RA PD 87333
TM 9-867
Do not use a cone-pointed
punch to drive out a pin. The
punch may spread the pin and
ruin the work. Use a pin punch
or taper punch to do this work.
Storage
WRONG
RA PD 87334
Coat punches with rust preventive compound (thin film),
and store in a dry place. Upon
removal from storage, wash
with dry cleaning solvent to
remove compound.
76
RIGHT
RA PD 87335
TM 9-867
Section XXI
REAMERS
HAND
POWER REAMER
EXPANSION REAMER
ADJUSTABLE REAMER
RA PD 87336
MAINTENANCE
Reamers, being precision cutting tools used for accurate sizing of
holes, must be used, handled, and stored with every precaution to
prevent denting, marring, or damage to the cutting edges.
Reamers must not be thrown into a tool box or allowed to lie
around unprotected on the bench.
Wrap reamers in slightly oiled cloths, using preservative lubricating oil (special), when they are not in use on the bench or in tool
crib storage.
Partitioned boxes or drawers make excellent tool crib storage.
Each reamer must have its own storage space.
77
TM 9-867
Adjustable Reamer Care
Adjustable reamers should not be adjusted beyond the maximum
size for which the reamer was made.
When using removable blade reamers, make sure the adjustment
has been properly made. The blades must be properly tightened
between the adjusting nuts. Any looseness may cause breakage
during use.
Misuses of Reamers
Turning a reamer backward to remove it from the work.
This results in dulling cutting edges, necessitating grinding to
resharpen. Grinding reamers makes them cut undersize. Always
turn forward (clockwise) with a reamer, using the same rotation for
removing as for cutting.
Turning a hand reamer with machine power.
This practice often breaks reamers, due to use of too much power,
jamming or fitting, and clogging. Avoid using hand reamers with
power.
Cleaning
Blow clean with air, wipe with a clean rag, and wrap in a rag
slightly dampened with oil.
Storage
Coat reamers with rust preventive compound (thin film) and store
in a dry place. Store in racks or divided boxes to protect cutting
edges from contact with metal. Upon removing from storage, wash
with dry cleaning solvent to remove rust preventive compound.
78
TM 9-867
Section XXII
SAWS
c
~KEYHOLE
5L.. -a
COMPASS
NAIL SAW
RA PD 87337
CLEANING AND OILING
(All Types of Saws)
Saws should be kept dry at all times. When necessary to use saw
under unfavorable weather conditions, wipe moisture from blade
after using. Always oil blade with a clean cloth dampened with
preservative lubricating oil (special) after using saw. Do not permit
blade to rust. Clean off all signs of rust from blade with crocus
cloth. Apply oil to blade after cleaning off rust.
SHARPENING WOOD-CUTTING SAWS
General
There are two general types of teeth used on wood-cutting hand
saws. Saws having one type of teeth are called rip saws and are
used for cutting with the grain of wood. Saws having the other
type of teeth are called crosscut saws. They are used to cut across
the grain of wood. Before attempting to sharpen saws, a clear
picture of the shape of these teeth is necessary.
835846 0 - 49- 6
79
TM 9-867
TOP VIEW OF CROSSCUT TEETH
TOP VIEW OF RIP TEETH
_FKERF
R
-t
-I
TEETH OF RIP SAW
TEETH OF CROSSCUT SAW
Compare the teeth illustrated and note the difference. Rip saw
teeth are shaped and filed to cut like chisels. Crosscut saw teeth
are shaped and filed to cut like knives.
Sharpening a saw consists of four steps: jointing, shaping, setting,
and filing. These are covered below. Do them in the order given.
Jointing a Saw (Rip or Crosscut)
WHY JOINT A SAW? All
teeth of a saw must be the same
height. Points or cutting edges
must be in a straight line. Low
teeth do not cut. High teeth dig
in and cause a saw to jump or
buckle. A saw is jointed by
filing down high teeth so they
are same height as low teeth.
Note uneven teeth in illustration.
THIS RIP SAW NEEDS JOINTING WHICH
IS THE FIRST STEP IN SHARPENING
RA PD 87339
How to Joint a Saw
Place a mill file flat upon teeth with length of file parallel to length
of saw. Run file over full length of saw until file touches tops of
all teeth.
SHOP-MADE WOODEN
GUIDE FOR HOLDING
JOINING FILE
JOINING A HAND SAW
80
RA PD
87340
TM 9-867
CAUTION: Check to see that all teeth are in a straight level line
as in following illustration.
Shaping Teeth (Rip or Crosscut)
1. After teeth have been jointed,
they must then be evenly spaced
and of same size and shape as
when saw was new. Determine
how teeth look when new by
examining unused teeth near butt
of saw.
SAME SAW AS ILLUSTRATED
2. Place file well down in gullet
ON PREVIOUSPAGE
and file straight across saw at
right angles to blade-never otherwise. If teeth are of unequal size,
press file against largest tooth
until center of flat top made by
jointing is reached. Move to next
gullet and file until tooth has
been brought to a point. Some'
times width of flat top indicates
a new gullet should be carefully
filed.
3. It is sometimes necessary to
repeat process of jointing and
shaping to assure a perfect job
The teeth now shaped and of
even height are ready to set.
RIP TEETH SHAPED AND READY TO SET
RA PD 87341
Setting Saw Teeth (Rip or Crosscut)
General. Saw teeth must be "set" or bent outward to right and
left alternately. This causes saw to cut a kerf sufficiently wide to
keep blade from bending or sticking in cut. Never set teeth more
than one-half the depth of teeth. Teeth may be set with or without
a saw set. Both methods are given below. Use the saw set if
available.
Using Saw Set. Place a saw set on saw so guides are over teeth with
anvil behind tooth to be set. Adjust anvil in frame to give desired set
(not over one-half the depth
of teeth). Press the saw set
1
FLUNGER--
BLADE OF
SAW
handles together. This causes
plunger to press tooth against
anvil and bends it to the angle
of bevel of the anvil. Similarly
set every second tooth. Reverse
saw set and set alternate teeth
same amount in opposite di-
RA PD 87342
ANVIl (BEVELED AT TOP FRONT EDGE)
rection.
81
TM 9-867
Without Saw Set. Prepare a steel
or hardwood block similar to
sketch. Dimensions shown are
minimum; block may be larger.
Angle of the bevel must be determined by examination of the saw
to be set; however, angle A must
be not less than 146 degrees or
saw teeth will break off when set.
BEVEL
3
RA PD 87343
Place saw on block as shown in
sketch. Clamp saw and block
together. Place a blunt end punch
on tooth to be set. Strike punch
smartly with a hammer to set
tooth. Similarly set every second
tooth which is over block. Move
block
along
to
PUNCH
SAW BLADE
set remaining
BLO
BLOCK
teeth. Apply block to other side
of saw to set alternate teeth.
RA PD 87344
FILING THE RIP SAW
Number of teeth per inch determines point size of saw; for example,
a saw having eight teeth per inch of blade is an 8-point saw. For
filing 4y/2
, 5-, or 6-point saw, use a 7-inch slim taper file; for
9- and 10-point saws, use a 5- or 5X2-inch slim taper file.
CLAhMrP
4
HANDLE
FILE
BLADE
RA PD 87344A
FIRST POSITION FOR FILING RIPSAW
1. Joint saw lightly as an aid to filing.
2. Place saw in filing clamp with handle at the right. Bottom of
tooth gullets should be Y8 inch above jaws of clamp. If more of
blade projects, file will chatter or screech. This will dull file
quickly. Start at point of rip saw indicated in above illustration.
Pick out first tooth set toward you. Place file in gullet to left of
this tooth. Hold file level and at angle indicated (right angle). File
should set well down in gullet. Study unworn teeth near handlefactory shaped teeth are an excellent guide.
82
TM 9-867
-'FILE
o'er~~~1
POSITION OF FILE BETWEEN TEETH
N\
AMOUNT OF TOOTH FILED AWAY IN
FIRST POSITION
RA PD 87345
File should cut on push stroke. It files back of tooth to left and
front of tooth to right at same time. File teeth until one-half of flat
tops, made as a guide, are cut away. Lift file from gullet and skip
next gullet to right. Place file in second gullet toward handle.
Repeat filing operation at same angle as before, and continue
skipping one gullet until you reach handle end of saw.
3. Turn saw blade around in clamp, placing handle of saw to left.
Take position indicated in following figure.
HANDLE
I
SECOND POSITION FOR FILING RIPSAW
Place file in gullet to right of first tooth set toward you. This is
the first of gullets you skipped
when filing other side of saw. At
correct angle (right angle), file
until you cut away other half of
flat top and teeth are shaped to
points. Continue this operation
AMOUNT OF TOOTH FILED AWAY
in every second gullet until you
IN SECOND POSITION
reach saw handle. All teeth
RA FD 87347
should be same height and shape.
FILING CROSSCUT SAW
Crosscut saw filing is exactly the same as rip saw filing with one
highly important exception-the angle at which file is held. A crosscut saw is filed so teeth have a 45-degree bevel. Handle end of file
is held about 15 degrees below the horizontal. Study following
illustrations.
83
TM 9-867
450
FIRST
POSITION x
FS CLAMP
LFILE
/,I
=.-.
n.... T
BLADE
=
._..A..]
HANDLE
FILE
E
450
/
"/.~
i
m. SECOND
_
HANDLE
BLADEC
HANDLE
BLADE
MPOSITION
CLAMP \
FILE
FILING CROSSCUT SAW
RA PD 87348
After one side of saw is filed, turn it around and file other side.
Never file all teeth from same side, as this causes saw to run to one
side.
NOTE: Variations in bevel in crosscut saw for work on medium or
hard woods are desirable, but only experience will indicate what
is best.
Additional Filing Hints
1. Tighten clamp securely to reduce vibration.
2. Use file recommended for work.
3. Adjust stroke so file is eased into gullet.
4. File at rate of about 60 strokes per minute-no more.
5. Use long, steady, uniform stroke.
6. Raise file on return stroke.
7. Exert enough pressure on file to keep it cutting on forward
stroke. Do not slide file.
8. Shape teeth with a worn file. Sharpen with a new one.
84
TM 9-867
REPLACING HANDLES
(Most Types of Saws)
Remove the special screws and nuts which attach handle to blade.
Slide handle off blade. Position new handle on butt end of blade
with screw holes in handle and blade alined. Install the special
screws and nuts which attach handle to blade.
Common Misuses (Wood-cutting Saws)
Do not lay saws on floor or place loose in a tool box. Such treatment may lead to dulled or bent teeth or sprung blades. Hang saws
up when not in use.
WRONG
¶
RIGHT
4·
RA PD 87349
Never saw into nails with a wood-cutting saw. This will dull, bend,
or break teeth. Remove nails from repair or alteration work before
sawing.
RIGHT
WRONG
RA PD 87350
Do not twist off strips of waste with blade. This dulls and bends
teeth and may spring blade. Break off strips of waste with hand
or mallet.
WRONG
RIGHT
85
i RA PD
87351
TM 9-867
Do not allow waste side of work to break off as cut is made. This
practice causes work to split. Support waste side and cut clear
through work.
WRONG
RIGHT
RA PD 87352
Do not allow end of saw to strike floor. There is danger of springing
the blade. Raise work high enough to get clearance. If work cannot
be raised, limit the stroke.
4'
:000:
/j\N
// t\:
RA PD 87353
Care and Adjustment of Hacksaws
Select blade with proper number of teeth per inch to handle job at
hand. Following table shows blades to use for various jobs to be
done with hand hacksaws.
Material
Teeth Per Inch
Aluminum ..............................
14
Brass--cast (soft) .......................
18
Brass--cast (hard) ......................
18
Brass tubing ............................
24
Cast iron ...............................
18
Copper .................................
14
Cold-rolled steel ........................
18
High-speed steel ........................
18
Iron pipe conduit ........................
24
Steel tubing ............................
24
Structural steel .........................
18
Tool steel ..............................
18
Install blade in frame to cut on forward stroke. When in use, make
tension of blade great enough so it cannot buckle under pressure
86
TM 9-867
of the stroke. On the other hand, do not strain blade so much that
slight canting of the frame will break it.
Relieve blade tension when saw is not in use.
Common Misuses (Hacksaws)
Do not attempt to do job with wrong type blade. It makes work
hard to do and results in blade spoilage. Use blade recommended
in table under "Care and Adjustment of Hacksaws," on page 86.
TEETH TOO SMALLTEETH
NO CHIP
TOO COARSECLEARANCESTRADDLES
TEETH CLOG
WORK
WRONG
COARSE TEETHAMPLE CHIP
CLEARANCE
TWO OR MORE
TEETH ON
METAL
RA PD
RIGHT
87354
Do not attempt to cut insecurely fastened work. Blade breakage
often results. Anchor work securely.
RIGHT
iRON
RA PD 87355
Do not use a new blade in a cut started with another blade. The
new blade is likely to wedge and break. Turn work over and start
new cut from opposite side.
WRONG
RIGHT
-I..
RA PD 37356
87
TM 9-867
"C--
'I'll,
Never start cuts on sharp
angles. This practice is likely
to strip saw teeth. Start the
cut with blade held at a slight
angle to the surface.
WRONG
RA PD 87357
RIGHT
RA PD 87358
Do not install blade so teeth point toward handle. Blade will not
cut properly. Point teeth away from handle, tighten securely, and
retighten after first few strokes.
RIGHT
WRONG
RA PD
87359
Do not apply too great or insufficient pressure to blade. Either
abuse ruins blades. Apply just enough pressure on face stroke to
make teeth "bite."
CORRECT PRESSURE-BLADE
CUTS ON FORE STROKE
RA PD 87360
TOO GREAT PRESSUREBLADE BREAKS
Storage
Apply rust preventive compound (thin film) to blades to prevent
rust, and store so teeth will not be dulled by contact with other
tools. Upon removal from storage, wash metal parts with dry
cleaning.solvent to remove compound.
88
TM 9-867
Section XXIII
SCRAPERS
FLAT SCRAPER
CARBON
SCRAPER
SINGLE HANDLE
BOX SCRAPER
THREE CORNERED
BEARING SCRAPER
BEARING SCRAPER
RA PD 87361
CARE AND CLEANING
Protect cutting edges of bearing scrapers by enclosing blade in a
cloth case when not in use.
Keep scrapers clean at all times. Wash them in dry cleaning
solvent and wipe them with a clean cloth.
SHARPENING
Bearing Scrapers
CROSS SECTIONS OF
BEARING SCRAPERS
RA PD 87362
Select an oilstone "slip" of exactly
the right size to fit interior bevel
of hollow-ground scraper. Hold
scraper firmly on a bench and rub
slip back and forth full length of
bevel a few times.
Flat Scrapers
Flat scrapers are sharpened with a file or on an oilstone, forming a
bevel on one side only.
89
TM 9-867
BOX SCRAPERS
General
Two types of edges are used
on box scrapers, square
turned edge and bevel turned
edge. For fine work, use
square turned edge; for fast
work, use bevel turned edge.
RIGHT
_
RIGHT
SQUARE TURNED
EDGE
Square Turned
Edge
BEVEL TURNED
EDGE
_4.-
Adjust guide of a fine abrasive wheel to right angles
with face of wheel. Grind tip
of scraper blade, as illustrated, until perfectly square.
Clamp blade in vise and
smooth off edge with a fine
mill file. Use care to keep
edge flat and at right angles
to sides of blade.
Use a burnishing tool or a
smooth piece of steel such as
the heel of a file or the side
of a chisel blade to rub the
scraping edge of tool as illustrated. Use considerable pressure. Stop burnishing as soon
as the edges are turned as
illustrated.
U.
Bevel Turned Edge
RA PD 87368
Adjust rest of an abrasive wheel to get a bevel of about 45 degrees.
Grind scraper as illustrated until indicated bend is obtained. Dip
frequently in water to prevent burning. Do not grind away more
metal than necessary to obtain a nick-free and straight bevel.
I II
SIDE VIEW
I
TOP VIEW
90
CORRECT BEVEL
RA PD
87364
TM 9-867
Place bevel flat on a fine oilstone.
Swaying the entire body from the
feet, rub blade (in a figure eight
motion) over surface of stone.
Brush feather edge from scraper
by rubbing flat side of blade
lightly over stone.
%
<
Clamp blade in vise as illustrated. With a burnishing tool,
or other piece of flat smooth steel,
rub edge with sufficient pressure
to turn it as shown in sketch.
.
Common Misuses
Do not use scrapers as chisels,
screwdrivers, knives, awls, or
punches. Such use will dull the
scraper, and may bend
or break it. Use tools
RA PD 87365
which they are intended.
(0
WRONG
RA PD
87366
WRONG
Never toss scrapers into
boxes or onto other tools
when not in use. Their
edges will be dulled. Keep
scrapers in racks or divided boxes when not in
use.
R
-
RA PD 87367
I
RA PD 87368
Storage
Coat scrapers with rust preventive compound (thin film) at time
of storing, and store in a dry place. Upon removal from storage,
wash metal parts with dry cleaning solvent to remove rust preventive compound.
91
TM 9-867
Section XXIV
SCREWDRIVERS
CROSS RECESS (PHILLIPSI
RA PD 87369
CARE AND CLEANING
Wash grease and grime from screwdrivers with dry cleaning solvent.
Scour rust from blade with crocus cloth or aluminum oxide abrasive
cloth. Keep blade coated with a film of preservative lubricating oil
(special) or engine oil (SAE 10). Lubricate spirals and friction
surfaces of spiral ratchet screwdrivers with preservative lubricating
oil (special) or engine oil (SAE 10).
GRINDING
Standard Type Screwdriver
Screwdriver
from lifting
CAUTION:
prevent loss
tips should be ground with sides parallel to keep tool
from screw slot when in use.
Dip screwdriver in water frequently during grinding to
of temper by overheating.
RIGHT
SIDES OF TIP
ARE PARALLEL.
TOOL WILL NOT
LIFT WHEN TWIST
IS APPLIED
RIGHT
U
WRONG
SIDES OF TIP
ARE SLIGHTLY
HOLLOWED OR
SHAPE OF
GRINDING WHEEL
SIDES ARE GROUND
AT AN ANGLE IN
AN ATTEMPT TO
MAKE TOOL WORK
IN ANY. SIZE SCREW.
RA PD 87370
92
TM 9-867
1. Adjust rest to hold screwdriver at right angles to grinding
surface of wheel. Grind end square. Do not grind away more
material than necessary to remove nicks and "square up" end.
2. GRIND SIDES
1. REMOVE NICKS
RA PD 87371
2. Adjust rest to hold screwdriver against wheel to give desired
parallel or concave shape. Grind both sides until tip is of required
thickness.
Cross Recess and Clutch Head Screwdrivers
Tools of this type require special holding fixtures to grind. In an
emergency, these tools can be shaped by grinding or filing. Use
care to maintain original angles and bevels.
Tempering
If hardened tip has been broken off or ground away, or if tool has
been heated, screwdriver must be hardened and tempered.
Heat about one and one-half inches of tip of blade to cherry
red with a gasoline torch, gas furnace, or charcoal fire. Dip about
3/4 inch of tip in clean, cold water. Quickly rub hardened end with
aluminum oxide abrasive cloth or oilstone to brighten it. Watch
color creep back into tip from heated portion of blade. Quench
when light blue color reaches tip.
,'aturn.
Polish blade with
emery cloth and
crocus cloth in
Grind blade
to proper shape.
Common
Misuses to
Avoid
WRONG
RA PD 87372
Do not use a
screwdriver as a
pry bar. It will
bend or break. Use
pry bar for prying.
93
PBAR
RIGHT
RA PD 87373
TM 9-867
63,
Never use a screwdriver for a chisel.
Such use may break
or bend the screwdriver. Use a chisel
for chiseling.
RIGHT
.
WRONG
Do not use a screwdriver with blade
tipped in screwhead.
This is likely to break
the blade or screwhead. Keep screwdriver shank perpendicular to screwhead.
RIGHT
WRONG
/
Do not attempt to
use a wrong size
screwdriver. This
practice causes battered screwheads and
bent and broken
screwdriver blades.
WRONG
RA PD 87374
RA PD 87375
94
TM 9-867
Never use pliers or wrench on screwdriver blade. Blade is likely to
bend or point break off. Apply only what pressure can be put on
handle by hand.
WRONG
RIGHT
RA PD
87376
Storage
Spread rust preventive compound (thin film) over metal parts of
screwdrivers, and store in a dry place. Upon removal from storage,
wash metal parts with dry cleaning solvent to remove rust preventive compound.
835846 0 - 49 - 7
95
TM 9-867
Section XXV
SHEARS
STRAIGHT
BLADE
TINNER'S
SHEARS
RA PD
CURVED BLADE TINNER'S SHEARS
87377
CARE AND CLEANING
Wash grease or other dirt from shears with dry cleaning solvent and
dry with a soft cloth. Lubricate pivot screw or bolt with a drop
of preservative lubricating oil (special) or engine oil (SAE 10).
Scour rust from shears with fine aluminum oxide abrasive cloth.
Apply a light film of oil to shears with a cloth to prevent rust.
Keep pivot screw or bolt tight enough to prevent side play but not
tight enough to cause binding.
96
TM 9-867
GRINDING
General
Shears must be ground if cutting edge is nicked or if bevel is distorted from improper sharpening. Dull shears can usually be
sharpened on an oilstone without grinding. Never grind shears if
sharpening will suffice; most shears are useless after two or three
regrindings. A single bevel is used. It may be flat or concave. It
must not be convex. Study the following cross-section views of
correct and incorrect bevels.
RIGHT
I
L
BEVEL IS
PERFECTLY
FLAT OR
STRAIGHT
ACROSS
WRONG
BEVEL IS
ROUNDED OUT
FROM INCORRECT
GRINDING OR
SHARPENING
I
RIGHT
BEVEL IS
SLIGHTLY
CONCAVE OR
SHAPE OF
GRINDING WHEEL
WRONG
BEVEL IS
ON WRONG
SIDE.
SHEARS WILL
NOT CUT
Bevel angles vary with type of
work for which shears are used.
Bevel usually makes an angle of
from 60 to 85 degrees with flat
inside surface of blade. Papercutting and cloth-cutting shears
are usually ground to a 60-degree
bevel; tin-cutting shears are usually ground to a bevel of approximately 85 degrees. Bevel angle can
usually be determined by examining an undamaged portion of
blade. If bevel has been distorted
its entire length, examine an undamaged pair of similar type
shears to ascertain what correct
bevel should be.
97
I
I
WRONG
I
DOUBLE BEVEL i
IS USED.
SHEARS WILL
NOT CUT
|
BEVEL ANGLE
ANGLE "A" VARIES FROM 600 TO
85 ° DEPENDING ON USE FOR
WHICH SHEARS ARE DESIGNED
RA PD 87378
TM 9-867
Procedure
CAUTION: Use a fine grain wheel, properly dressed. Dip shears
into water frequently during grinding to prevent loss of temper.
1. Adjust rest to position which will give correct bevel.
2. Start wheel and place shears blade on rest, bevel side down.
Move blade into contact with wheel. Move shears blade continually
from side to side during grinding. Keep motion uniform to ensure
straight cutting edge.
3. Turn shears over on rest and grind other blade.
RA PD 87379
Sharpening
Apply blade to lightly oiled oilstone so flat surface lies flat on
stone with blade crossing stone at right angles. Draw blade smartly
across stone from heel to point, so as to remove wire edge. Start
each stroke at heel of blade. Stone other blade in same manner.
1
[
RA PD 87380
Common Misuses
Never use shears as screwdrivers, hammers, or pry bars. They
break easily. Use any tool only for the purpose for which it was
designed.
98
TM 9-867
RIGHT
WRONG
SCREWDRIVER -_
RA PD 87381
Do not attempt to cut heavier materials than shears are meant to
handle. It will dull and possibly break the blades. Use shears designed to do the job.
WIRECUTTERS
RIGHT
RA PD
87382
Never toss shears into a tool box They will become dull and are
likely to be broken. Hang them on hooks or lay them on an
uncrowded shelf when not in use.
WRONG
RIGHT
RA PD
87383
Storage
Apply rust preventive compound (thin film) to shears at time of
storing. Store in a dry place with cutting edges protected from
contact with other objects. Wash off rust preventive compound
with dry cleaning solvent upon removal from storage.
99
TM 9-867
Section XXVI
SOLDERING IRONS
SOLDERING COPPER
ELECTRIC
SOLDERING IRON
RA PD 87384
PREPARING FOR USE
Soldering Copper
This involves cleaning, heating, hammering, annealing, filing point,
and tinning. Some of these steps are not required every time a
copper is conditioned. To perform satisfactorily, a copper must
have a well-formed, well-cleaned, and well-tinned point.
1. File all old solder and scale from point end. This is important.
If neglected, solder and scale will prevent proper tinning of point.
RA PD 87385
100
TM 9-867
2. Heat copper to a dull red. Do not direct heat at point because
of danger of burning it. Use gas flame, blowtorch, or charcoal fire.
3. File point to proper shape. Point should taper back to efficient
working angle, depending on size of copper. Point should be slightly
rounded.
4. Plunge red-hot copper into cold water. This anneals copper,
making it softer for filing, easier to tin, and more efficient at
giving off heat.
5. File all rough spots from point end of copper, finishing with a
fine file to a flat, smooth surface. This polishing makes tinning
last longer.
6. Heat copper so it will just melt solder. Wipe copper on wet
rag to clean surfaces. Place a few drops of solder on block of
ammonium chloride (sal ammoniac). Rub copper on ammonium
chloride and in melted solder until copper acquires a bright tinned
surface.
AMMONIUM CHLORIDE
POOL
F SOLDER
TIN POINT
RA PD 87386
7. Clean tinned point each time it is removed from heater. When
pits form on copper back of tinned area, heat copper and dip in
water to remove scale.
Electric Soldering Iron
Shape and clean point by filing. Tin point in manner similar to
procedure for tinning soldering copper. However, do not use external source of heat and do not dip iron in water.
REPAIR
(Electric Soldering Iron)
1. If iron does not heat with plug installed in a "live" receptacle,
an open circuit is indicated in plug, cord, or element. Visually
inspect the parts to see if there is a bent plug prong or "pulled"
connection. Feel along length of wire for breaks inside insulation.
If open circuit cannot be found by visual inspection, disconnect
cord from iron. Test cord and element separately with test lamp.
Replace faulty part.
101
TM 9-867
2. If fuse "blows" when iron is plugged into receptacle, a short
circuit is indicated in plug, cord, or element. Inspect plug and cord,
looking for damaged insulation. If unable to locate short, test cord
and element separately, with test lamp. Replace short-circuited
parts.
Common Misuses
Do not leave electric soldering iron connected for long periods on
the chance it may be wanted. This practice is hard on elements
and wasteful of current. Disconnect electric soldering iron when
not in use.
QAI
00
WRONG
RIGHT
RA PD 87387
Do not throw coppers into tool box. There is danger of battering
the point. Hang coppers up or place on an uncrowned shelf when
not in use.
.
-
t
23_i
! !
i
'i ii
0I:ini
RIGHT
WRONG
\;
i _:ii
'! -i
II -! IN
!-,, 1
SE
I
_
RA PID
87389
Storage
Coat iron shaft and ferrule with rust preventive compound (thin
file), and store in a dry place.
102
TM 9-867
Section XXVII
TAPS AND DIES
TAPER TAP
PLUG TAP
ROUND SPLIT DIE
BOTTOMING TAP
DIE STOCK
PIPE DIE
HEAD AND
RATCHET
STOCK
PIPE DIE
!
'--TAP
WRENCHES
RA PD 87389
103
TM 9-867
CARE IN USE
Taps and dies are cutting tools whose use will result in much
breakage unless properly handled. This is due to their brittleness
and hardness.
Do not attempt to cut threads in hardened material. The result
would be a broken, chipped, or dulled tap or die.
Do not attempt to cut a thread with a die when the diameter of
the part to be cut exceeds the major diameter of the thread.
Drill tap drill holes to correct size. A hole that is too small will
cause the tap to bind and a broken tap will result.
Tap small sizes very carefully. Avoid any jerky motion or overpower, as a broken tap will result.
Aline tap properly with hole, as incorrect alinement will result
in a broken or worn tap.
h
TAP OUT OF
|
llALINEMENT
M~i
i
IN STARTING
WRONG
"*
HAND TAPPING-LINE
UP BY EYE OR WITH
A SMALL SQUARECHECKING FROM
BOTH SIDES
~~~~RIGHT
RA PD
87390
Dull taps break easily. Keep taps sharp.
Use of improper lubricant or insufficient lubricant causes undue
wear and breakage of taps and dies.
Lubricants for Hand Tapping
and Die-cutting Threads
Mild steel-Mixture of 75 % engine oil
(SAE 10) and 25% white lead.
High carbon and alloy steel-Lard oil.
Hard steel-Turpentine.
Brass-Lard oil.
Copper-Lard oil.
Aluminum-Dry cleaning solvent.
Monel metal-Lard oil and white lead.
RA PD 87391
Cast iron-Dry.
104
TM 9-867
For tapping blind holes, tap drill sufficiently deep so there is
amDle room for chips, or a broken tap will result.
CHIPS BIND TAP-DRILL HOLE DEEPER
TO PREVENT BINDING AND
RESULTANT TAP BREAKING
HOLE HAS SUFFICIENT DEPTH TO
KEEP CHIPS FROM BINDING
RA PD 87392
Remove all chips from a blind hole before using final bottoming
tap. This prevents breakage of bottoming tap.
Select proper size tap wrench. A large wrench on a small tap
may cause undue strain and breakage will result.
Taps must be kept in a box, as illustrated, when not in use.
RIGHT-HAVE AN ARRANGEMENT
SO TAPS AND DIES WILL NOT SIRIKE
EACH OTHER OR ANY OTHER TOOLS
RA PD 87393
WRONG
Sharpening Taps
Dull leading or chamfered threads cause much tap breakage. Keep
taps sharp by proper grinding.
RIGHT
RA PD 87394
105
TM 9-867
~~NO
CLEARANCE
WRONG
e
RIGHT
GRIND
CLEARANCE
RA PD
87395
Cleaning
Blow taps and dies clean with air and wipe off excess oil with a
clean rag after using. Place in rack or box after cleaning. Pipe
die head and ratchet must be partially disassembled before cleaning with air and rags.
Storage
Coat all parts with rust preventive compound (thin film) and
store in a dry place. Store in racks or divided boxes to protect
cutting edges from contact with metal. Upon removing from storage
wash with dry cleaning solvent to remove rust preventive compound.
106
TM 9-867
Section XXVIII
VISES
BLACKSMITH'S
VISE
MACHINIST'S VISE
PIPE VISE
UTILITY VISE
RA PD 87396
Cleaning
Wash grease and dirt from vise with dry cleaning solvent. Wipe
dry with a cloth. Clean jaws with a wire brush. Pick chips from
between serrations with a file scorer or a flattened iron wire.
Lubrication
Lubricate slide and worm lightly with preservative lubricating oil
(special) or engine oil (SAE 10). Lubricate sparingly; excessive
amounts help cause a messy shop.
Common Misuses
Do not use vise jaws as a heavy anvil. There is danger of breaking
jaws or battering inserts. Use an anvil for anvil jobs.
t\~ '.
7
7;0WRONG
LRIGHT
RA PD 87397
107
TM 9-867
Never use a pipe to increase handle leverage. There is danger of
bending or breaking the handle. Tighten only as tight as can be
done without an extension.
RIGHT
WRONG
RA PD 87398
Storage
Wash lubricants from vise with dry cleaning solvent. Dry vise thoroughly. Coat all surfaces of vise with rust preventive compound
(thin film) and store in a dry place. Upon removal from storage,
wash off the rust preventive compound with dry cleaning solvent.
108
TM 9-867
Section XXIX
WRENCHES
SOCKET HEAD
SET SCREW WRENCH
ADJUSTABLE WRENCHES
RA PD 87399
CLEANING AND CARE
Wash grease and dirt from wrenches with dry cleaning solvent.
Wipe dry with a clean cloth. Clean chips from jaw serrations with
a file scorer or flattened iron wire. Scour rust from wrenches with
crocus cloth or fine aluminum oxide abrasive cloth. Lightly coat
wrenches which show tendency to rust with preservative lubricating
109
TM 9-867
oil (special) or engine oil (SAE 10). Lubricate slide and worm of
adjustable wrenches with a drop or two of the oil.
MAINTENANCE
Grinding and Filing
Open-end and adjustable wrenches with battered, nicked, or spread
jaws can sometimes be made serviceable by grinding snd/or filing.
When attempting this repair, enlarge open-end wrenches to next
standard size. Make jaw faces perfectly flat and parallel. Dip wrench
in water frequently when grinding to preserve temper.
Removing Play from Adjustable Wrench
1. Remove screw which acts as worm axle from wrench. Lift worm
and worm spring from wrench.
2. Stretch worm spring. Insert spring into cupped end of worm
and reassemble wrench. Tighten worm axle screw securely.
3. Prick punch wrench adjacent to screw to lock screw in position.
DISASSEMBLE WRENCH
STRETCH WORM SPRING
LOCK SCREW
RA PD 874400
Renewing Pipe Wrench Jaw Serrations
Using a fine threecornered or taper file,
carefully deepen low
points between serrations.
'
Misuses
Do not push on a
WRONG
RA PD 87401
wrench. It's dangerous. Arrange work so
you can pull on
wrench.
110
RIGHT
RA PD 87402
TM 9-867
Never use a wrench which fits the nut poorly. This practice batters
nuts and spreads wrenches. Use correct size wrench.
WRONG
RIGHT
FRA PD 87403
Never turn adjustable wrenches so pulling force is applied to adjustable jaw. Wrench is likely to slip or break. Always turn wrench so
force is received by stationary jaw.
WRONG I-
RIGHT
RA PD 87404
Do not use pipe to increase wrench leverage. Wrench may bend or
break. Use longer wrench.
WRONG
RA PD
87405
RIGHT
Storage
Coat wrenches with rust preventive compound (thin film) and
store in a dry place. Upon removal from storage, wash with dry
cleaning solvent to remove rust preventive compound.
835846 0 - 49- 8
111
TM 9-867
Section XXX
REFERENCES
PUBLICATIONS INDEXES.
The following publications indexes should be consulted frequently
for latest changes or revisions of references given in this section and
for new publications relating to materiel covered in this manual:
1.
Ordnance supply catalog index (index to
ASF Cat.
SNL's) .............................
ORD 2
2.
Ordnance major items and combinations,
SB 9-1
and pertinent publications ..........
3.
List of publications for training (listing
CCBP's, FM's, FT's, MTP's, TB's,
TM's, TR's, TC's and LO's) .......... FM 21-6
4.
List of training films, film strips, and film
FM 21-7
bulletins ............................
5.
Military training aids (listing graphic
training aids, models, devices, and disFM 21-8
plays) ..............................
6.
List and index of administrative and supply
publications (listing new AR's, Cir's,
GO's, and WDP's, T/O & E's, T/O's,
T/E's, T/S's, T/BA's, MR's, RR's,
WDP's,SB's, MWO's, and Forms) .... WD Pam 12-6
STANDARD
1.
NOMENCLATURE LISTS.
Common Tool Lists.
Abrasion and compression tools (general
abrasives, hand grinders, hand presses,
ASF Cat.
sharpening stones, etc.) ................
ORD 5 SNL J-1
Benches, tool boxes, cabinets, bins, tool
chests, tool rolls, etc., of general application ASF Cat.
ORD 5 SNL J-15
Cutting, boring, and tweezer tools (saws,
shears, planes, files, rasps, chisels, bits,
reamers (hand), pliers, pincers, etc.)..... ASF Cat.
ORD 5 SNL J-2
112
TM 9-867
REFERENCES -
Contd.
Geometrical tools and instruments (squares,
compasses, rules, gages, calipers, micrometers, dividers, levels, protractors, scribers,
surface plates, etc.) ....................
ASF Cat.
ORD 5 SNL J-3
Hand tool appurtenances (file cleaners,
handles, heads, tool checks, tool racks,
etc.) .................................
ASF Cat.
ORD 5 SNL J-8
Lifting, holding, and forming tools (bit
braces, saw frames, vises, clamps, hoists,
block and tackle, molds for castings,
anvils, jacks and slings, etc.) ............ ASF Cat.
ORD 5 SNL J-5
Measuring and testing instruments (electrical, air, liquid, etc.) ..................
ASF Cat.
ORD 5 SNL J-9
Miscellaneous kits and tool-sets ...........
ASF Cat.
ORD 5 SNL J-20
Paint, spraying equipment and related items ASF Cat.
ORD 5 SNL J-14
Percussion, digging, and wrecking tools (hammers, mallets, mauls, sledges, axes, hatchets,
picks, mattocks, shovels, crowbars, pinch
bars, etc.) ............................
ASF Cat.
ORD 5 SNL J-6
Punch, drift, fastening, and scraping tools
(awls, needles, punches, drifts, screwdrivers,
wrenches, scrapers, riveters (hand sets),
etc.) .................................
ASF Cat.
ORD 5 SNL J-4
Small tools (twist drills, countersinks,
counterbores, cutting-off tool cutters,
cutters, etc.) ..........................
ASF Cat.
ORD 5 SNL J-10
Tire repair and maintenance tools and equipment .................................
ASF Cat.
ORD 5 SNL J-16
Welding, forging, soldering and brazing
equipment (blow-torches, soldering coppers,
melting ladles, and welding outfits) ....... ASF Cat.
ORD 5 SNL J-7
113
TM 9-867
REFERENCES -
Contd.
2. Maintenance Tool Lists.
Tools, maintenance, for repair of pack, light
and medium field artillery; and armament
of these calibers for airplane and combat
vehicles ..............................
ASF Cat.
ORD 6 SNL C-18
Tools, maintenance, for repair of small and
hand arms, and pyrotechnic projectors... ASF Cat.
ORD 6 SNL B-20
Tool-sets for maintenance of antiaircraft
ASF Cat.
artillery ..............................
ORD 6 SNL D-14
Section 2
Tool-sets for maintenance of antiaircraft
materiel (37-mm and 40-mm) ........... ASF Cat.
ORD 6 SNL A-35
Section 2
Tool-sets (common), specialists' and organiASF Cat.
zational ..............................
ORD 6 SNL G-27
Section 2
Tool-sets for maintenance of heavy field
ASF Cat.
artillery ..............................
ORD 6 SNL D-14
Section 1
Tool-sets for maintenance of sighting and fire
ASF Cat.
control equipment .....................
ORD 6 SNL F-272
Tool-sets for maintenance of small and intermediate caliber ground, aircraft, and
antiaircraft materiel; cannon and mortars. ASF Cat.
ORD 6 SNL A-35
Section 1
Tool-sets (special), motor vehicles ......... ASF Cat.
ORD 6 SNL G-27
Section 1
3.
Shop Loads Tool Lists. (truck and railway)
Car, railway, machine shop, M1 (for ordnance company, maintenance-railway
ASF Cat.
artillery) .............................
ORD 7 SNL E-53
114
TM 9-867
REFERENCES -
4.
Contd.
Truck, 214-ton, 6 x 6, small arms repair, M7,
M7A1, and M7A2 .....................
ASF Cat.
ORD 7 SNL G-138
Truck, 21/ 2-ton, 6 x 6, automotive repair, M8
and M8A1 .............................
ASF Cat.
ORD 7 SNL G-139
Truck, 214-ton, 6 x 6, artillery repair, M9
and M9A1 ............................
ASF Cat.
ORD 7 SNL G-140
Truck, 21 2-ton, 6 x 6, instrument repair, M10
and M1OA1 ...........................
ASF Cat.
ORD 7 SNL G-141
Truck, 21 2-ton, 6 x 6, welding, M12 and
M12A1 ...............................
ASF Cat.
ORD 7 SNL G-142
Truck, 214-ton, 6 x 6, tool and bench, M13. ASF Cat.
ORD 7 SNL G-143
Truck, 2 1 2-ton, 6 x 6, machine shop, M16,
M16A1 and M16A2 ....................
ASF Cat.
ORD 7 SNL G-146
Truck, 21/ 2-ton, 6 x 6, electrical repair, M18,
M18A1, and M18A2 ...................
ASF Cat.
ORD 7 SNL G-149
Truck, 214-ton, 6 x 6, instrument bench, M23 ASF Cat.
ORD 7 SNL G-178
Truck, 214-ton, 6 x 6, Signal Corps general
repair, M31; Truck, 21 2-ton, 6 x 6, small
arms repair (Signal Corps), M7......... ASF Cat.
ORD 7 SNL G-229
Truck, tire repair, 21 2-ton, 6 x 6, M32
(Loads A and B) and Trailer, tire repair,
1-ton, 2-wheel, M25 (Loads A and B).... ASF Cat.
ORD 7 SNL G-234
Truck, 214-ton, 6 x 6, Signal Corps repair,
M30 .................................
ASF Cat.
ORD 7 SNL G-235
Ordnance maintenance sets ...............
ASF Cat.
ORD 6 SNL N-21
Organizational Tool Lists.
Special ammunition surveillance, testing,
inspection, and renovation tools and
supplies ..............................
ASF Cat.
ORD 5 SNL P-ll
115
TM 9-867
REFERENCES -
Contd.
Tool-set, unit equipment, special for posts,
ASF Cat.
camps and stations ....................
ORD 6 SNL N-23
Tool-sets, for ordnance service command
ASF Cat.
automotive shops ......................
ORD 6 SNL N-30
5.
Cleaning and Preserving.
Cleaning, preserving and lubricating materials; recoil fluids, special oils, and miscellaneous related items ...................
ASF Cat.
ORD 5 SNL K-1
Lubricating equipment, accessories and
ASF Cat.
related dispensers ......................
ORD 5 SNL K-3
Soldering, brazing and welding materials,
ASF Cat.
gases and related items .................
ORD 5 SNL K-2
EXPLANATORY PUBLICATIONS.
Basic maintenance manual ................
Cleaning, preserving, sealing, lubricating and
related materials issued for ordnance
materiel ..............................
Dictionary of United States Army terms...
Ordnance Maintenance: Tire repair and
retread ...............................
Welding, theory and application ...........
116
U.S. GOVERNMENTPRINTINGOFFICE: 0-1949
TM 37-250
TM 9-850
TM 20-205
TM 9-1868
TM 9-2852